MAN B&W Diesel lndentification No.

for lnstrution Book

lndentication No. for Description: 000.00

/L Function
Section NO

Tl L
lndentication No. for Working Card: 000-00.00
Sub-function
Function
Section No.

lndentication No. for Plate: 00000-00 H

H for Holeby
Edition
Section No. and Function

For ordering of spare parts,see page 500.50

Zhenjiang Marine Diesel Works

Add: 250,Guantangqiao
Zhenjiang
Jiangsu Province
P.R.China
Tel. +86 51 1 451 1880
Fax: +86 51 1 451 0033
 MAN
z JMD--/B=W\
Engine Date

;Main data for engine i5oC.QO (Q3H) Il

I

liiltroduction ,st3avax(02) 1
I
-- --
r-- ,
/Safety
_ P - - - - - - l
isae.am ( a 2 ~ ) :
I

/Cross section 15tsk3.05 (05H) I

F- -- pp----

,
/Key for engrne desrgnatron j50t~.lCb ( 0 2 )
F---
;Designation of cyl~nders j5~i3.11(-33Hj ,
kngine rot2:;on clockwise i 5 ~ c . 1 2(OZHf I
,
- .
--U
-- - . --

:Code ~ d e n t ~ f ~ c a tfor
l o n~nstruments i500.20 (02H]
I-- - - l
I
iIr;trrtci[i!lion to planned marntenance programme 1500.24 (03E) i
p-

i ~ l a n n e imaintenance
l programme, majoi-
love, I sul/inspect~orl
/planned maintenance programme, dutles during
j 1500.26 (G$!+)
!operation
l . ......-.......... . ~ . .... -- - . . . .

/Operation
. data and set points i s ~ ~ . (343;
33 . . . . . . .
i,
7-
...... . , -. . . . . ~. .~

! ~.. a t a
1
for. . .pressure and tolerance
............................ ... . . . . . . . .
i500.35 ( W E ) . . . . . - -.. !
( ~ a t for
a tightening torque i50?2.4C?(06H)~- - !
C.-.- .......... .......
...~-- . . ..... .---L-------- /
!Declaration
I .._
_ ..._of weight /580.45 (82H)
... _ --
,j

,I
_.... ..-_. . . . . . . ........ . . _. ..... . i
l I
,/Ordering of spare parts . / 5.0 0. . S C..(CB1.R')
-............. . . . .- . L.. ............
.-

Iservice letters l50@.55 (alH)

;i:i
1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
m ................... - ......... . .-c
onver version table
I_-._
...........................
p p
- . . . . . . . . . . . . . .
j500.60 (OPgi)
l . . - -
:l
l1- ~ a-s i csymbols
. - .-
for
...
piping
. . . . . . . . ..... ..---..p _-
 Description
Page I (1) Warning 000.00

General

Warning !

(Marine engines only)

It is important that all MAN B&W Diesel AIS engines

are operated within the given specifications and
performance tolerances specified in the engines'
Technical Files and are maintained according to the
MAN B&W Diesel AIS maintenance instructions in
order to comply with given emissions regulations.

In accordance with Chapter I of the Code of Federal

Regulations, Part94, Subpart C, s94.21 'l NOTICE is
hereby given that Chapter I of the Code of Federal
Regulations, Part 94, Subpart K, s94.1004 requires
that the emissions related maintenance of the diesel
engine shall be performed as specified in MAN BBW
Diesel AIS instructions including, but not limited to,
the instructions to that effect included in the
Technical File.

03.38 - ESO 0406

 i MAN 'i
ZJMD - =&W g B&W P
Description 500.00
Page 1 (1) Main Data for Engine Edition 03H

Cycle 4-stroke

Configuration In-line

Cyl. Nos. available 5-6-7-8-9

Power range 450-900 kW (610-1220 BHP)

Speed 100011200 rpm

Bore 160 mm

Stroke 240 mm

Strokelbore ratio l.5:1

Piston area per cyl. 201 cm2

Swept volume per cyl. 4.8 Itr.

Compression ratio 15.23

Max. combustion pressure 170 bar

Turbocharging principle Constant pressure system and infwcc >ling

Fuel quality acceptance HFO up to 700 cSt150° C (BSMA 100-M9)

Power lay-out MCR version

Speed rpm l000 1200

Mean piston speed mlsec. 8 9.6

Mean effective pressure bar 22.4 20.7

Max. combustion pressure * bar 170 170

Power per cylinder kW1cyl. 90 100

BHPlcyl. 122 136

Overload rating (up to 10%) allowable in 1 hour for every 12 hours

Power per cylinder kWlcyl. 99 110

BHPlcyl. 134 150

99.43 - ESl
 Description 500.01
Page 1 (1) Introduction Edition 02

General
Description

This instruction book serves the purpose to provide
general information for operation and maintenance,
and to describe the design. It can also be used as a
reference when ordering spare parts.
Reliable and economical operation of the plant is
conditional upon its correct operation and mainte-
nance in accordance with MAN B&W Diesel AIS'
instructions. Emissions related maintenance of the
diesel engine shall be performed as specified in
MAN B&W Diesel N S ' instructions and any addi-
tional instructions to that effect included in the Tech-
nical File. Consequently, it is essential that the
engine room personnel are fully acquainted with the
contents of this book and, in respect of instructions
on ernjssions related maintenance of the diesel
engine, also the additional instructions to that effect
set out in the Technical File.

The book is a basic instruction manual for the par-

ticular engine supplied, with plant-adapted infor-
mation such as basic media-system drawings, elec-
trical wiring diagrams and test bed reports.

The first five sections (500-504) of the bookserve as

a guide to engine operation, and the next fifteen
sections (505-519) coMain lechnical descriptions,
spare parts illustrations wl.,, opurtenant parts lists,
as well as working cards.

The last section (520) comprises tools.

l
Fig. I Structure of instruction book.
The engine is divided into a number of main com-
ponentslassernblies, each of which is described in
a section of this book (section 505-519).

Each of these sections starts with technical de-

scriptions of the systemslcomponents, followed by
working cards and the spare parts illustration plates
and parts lists.

03.36 - ESO 0406

--
Description 500.02
Page 1 (2) Safety Edition 02H

General

General Spares

Proper maintenance,which is the aim of this book, is
a crucial aspect of achieving optimum safety in the
engine room. The general measures mentioned
here should, therefore, be a natural routine for the
entire engine room staff.
Large spare parts should, as far as possible, be
placed well strapped nearthearea of use and should
be accessible by crane. The spare parts should be
well-preserved against corrosion and protected
against mechanical damage. Stock should be
checked at intervals and replenished in time.

Cleanliness
The engine room should be kept clean above and
below the floor plates. If grit or sand blows into the
engine room while the ship is in port, the ventilation
should be stopped and ventilating ducts, skylights,
and doors in the engine room should be closed.
Light
Ample working light should be permanently installed
at appropriate places in the engine room, and port-
able working light in explosion-proof fittings should
be available everywhere.

In particular, welding or work which causes the

spreading of grit and chips must be avoided nearthe
engine, unless this is closed or covered, and the
turbocharger air intake filters are covered.
The exterior of the engine should be kept clean and
the paintwork maintained, so that leakages can
easily be detected.
Freezing
If there is a risk of damage due to freezing when the
plant is out of service, engines, pumps, coolers and
pipe systems should be emptied of cooling water.
Warning

Fire Opening of cocks may cause discharge of hot liquids

or gases. Dismantling of parts may cause springs to
If the crankcase is opened before the engine is cold, be released.
- welding and the useofnaked lightwill involvetherisk
of explosions and fire. The same applies to inspec- The removal of fuel valves (or other valves in the
tion of oil tanks and the space below the cooler. cylinder head) may cause oil to run down to the
Attention should furthermore be paid to the danger of piston crown, and if the piston is hot an explosion
fire when using paint and solvents with a low flash may then blow out the valve.
point. Porous insulating material drenched with oil
from leakages is easily inflammable and should be When testing fuel valves with the hand pump do not
renewed. See also: "Ignition in Crankcase" in sec- touch the spray holes, as the jet may pierce the skin.
tion 503. Consider beforehand which way the liquids, gases
N
7 or flames will move, and keep clear.
m
9
Order
5
Ln
N
Crankcase Work
z Hand tools should be placed to be easily accessible
Q
on tool boards. Special tools should be fastened to Check beforehand that the starting air supply to the
tool panels (if supplied) in the engine room close to engine is shut off.
0
the area of use. No major objects may be left
unfastened, and the floor and passages should be
kept clear.

01.32 - ESO 0406

 500.02 Description
Edition 02H
Safety Page 2 (2)

General

F e e l i n g Over Turning with Air

Whenever repairs or alterations have been made to
the running gear, apply the "feel-over sequence"
until it is ensured that there is no undue heating, oil-
mist formation, blow-by, or failure of cooling water or
lubricating oil systems.
After prolonged out-of-service periods or overhaul
work which may involve a risk of accumulation of
liquid in the combustion spaces, turning should
always be effected through at least two complete
revolutions.

Feel-over S e q u e n c e Check and Maintain

Feel overafter5-l5 and 30 minutes'idle running and Lubricating oil condition, filter elements and measur-
finally when the engine is running at full load. See ing equipment, see "Planned Maintenance Pro-
also "Operation" in the section 501. gramme".

-
--
--
m
---
--- -----
-- -
- ----
L=-=

GENEWATK SETS
01.32 - ESO
 ZJMD - =&W

Description
Page 1 (1) Cross Section 1 500.05
Edition 05H
1

99.40 - ES1 0406 -----

=
b
-
----- ---
---
Fe-

CENERP;TNC SETS
m
Description 500.10
Page 1 (1) Key for Engine Designation Edition 02

General

Engine Type Identification

The engine types of the MAN B&N1programme are identified by the following figures:

Engine Type d

Cyl. diamlstroke

~ e s ' i g nVariant I

Rating

MCR : Maximum continuous rating

ECR : Economy continuous rating
l Description
Page 1 (1)
ZJMD -/B&W\
MAN

Designation of Cylinders
~~
Edition 03H

General

Front end Flywheel end

Exhaust side / Right side

Service side / Fuel Pump side 1 Left side

 Description 500.12
Page I(1) Engine Rotation Clockwise Edition 02H

General

Direction "Clockwise" of diesel engine seen from flywheel end

r'
Alternator

98.18- ES1 0406 --

-
-
--ze==
-v---
---
----
-=--
CENERATNC SETS
 ZJMD - 6&W

Description 500.20
Page 1 (2) Code Identification for Instruments Edition 02H

General

Explanation o f Symbols

Measuring device
Local reading

Temperature Indicator
No. 40 "

Measuring device
Sensor mounted on enginelunit
QV Readinglidentification mounted in a panel on the enginelunit

Pressure lndicator
No. 22 *

Measuring device
Sensor mounted on enginelunit
Readinglidentification outside the enginelunit

Temperature Alarm High

-
No. 1 2 "

* Refer to standard location and text for instruments on the following pages.

Specification of letter code for measuring devices

I st letter Following letters

F Flow A Alarm

L Level D Differential

P Pressure E Element

S Speed H High

T Temperature I Indicating

U Voltage L Low

V Viscosity S Switching, Stop

X Sound T Transmitting

Z Position X Failure
 500.20 Code Identification for Instruments
Description
Edition 02H Page 2 (2)

General

Standard Text for Instruments

Diesel EnginelAlternator

LT Water System
01 inlet to air cooler 04 inlet to alternator 07 inlet to lub. oil cooler
02 outlet from air cooler 05 outlet from alternator 08 inlet to fresh water cooler (SW)
03 outlet from lub. oil cooler 06 outlet from fresh water cooler (SWj 03

HT Water System
10 inlet to engine 14 inlet to HT air cooler 17 outlet from fresh water cooler
10A FW inlet to engine 14A FW inlet to air cooler 18 inle! to fresh water cooler
11 outlet from each cylinder 148 FW outlet from air cooler 19A inle! to prechamber
12 outlet from engine 15 outlet from HT system ?9B outlet from prechamber
13 inlet to HT pump 16 outlet from turbocharger

Lubricating Oil System

20 inlet to cooler 24 sealing oil - inlet engine 28 level in base frame
21 outlet from cooler Iinlet to filter 25 preiubricating 29 main bearings
22 outlet from filter Iinlet to engine 26 inlet rocker arms and roller guides
23 inlet to turbocharger 27 intermediate beating lalternator bearing

Charging Air System

30 inlet to cooler 34 charge air conditioning
31 outlet from cooler 35 surplus air inlet
32 jet assist system 36 inlet to turbocharger
33 outlet from TC filter / inlet to TC compr. 37 charge air from mixer

Fuel Oil System

40 inlet to engine 44 outlet from sealing oil pump
41 outlet from engine 45 fuel-rack position
42 leakage 46 inlei to prechamber
43 inlet to filter 47

Cooling 'Oil System

50 inlet to fuel valves
51 outlet from fuel valves
52
53

Exhaust Gas System

60 outlet from cylinder 64
61 outlet from turbocharger 65
62 inlet to turbocharger 66
63 67

Compressed Air System

70 inlet to engine 74 inlet to reduction valve 78 inlet to sealing oil system
71 inlet to stop cylinder 75 microswitch for turning gear 79
72 inlet to balance arm unit 76 inlet to turning gear
73 control air 77 waste gate pressure

Load Speed
80 84 88 index -fuel injection pump
81 overspeed 85 microswitch for overload 89 turbocharger speed
82 86 90 engine speed
83 87

Miscellaneous
91 natural gas - inlet to engine 94 cylinder lubricating
. 92 oil mist detector 95 voltage
93 knocking sensor 96 switch for operating location
 ZJMD - =&W

Description 500.24
Page 1 (2) Introduction to Planned Maintenance Programme Edition 03H

General

General The front page indicates the following:

The overhaul intervals are based on operation on a
specified fuel oil quality at normal service output,
which means 70-100% of MGR.
In the long run it is not possible to achieve safe and
optimum economical running without an effective
maintenance system.
l ) Safety regulations,which MUST be carried out
before the maintenance work can start.
2) A brief description of the work.
3) Reference to any work which must be carried
out before the maintenance work can start.

The structure and amount of information in the main-
tenance programme mean that it can beintegrated in
the entire shipls!power station's maintenance sys-
tem or it can be used separately.
The core of the maintenance system is the key
diagram, see pages 500.25 and 500.26, indicating
the inspection intervalsforthe components!systems,
so that the crew can make the necessary overhauls
based on the engines' condition and!or the time
criteria.
4) Related procedures - indicates other works,
depending on the present work - or works
which it would be expedient to carry out.
5) lndicatesxnumberof meninxnumberofhours
to accomplish the work.
The stated consumption of hours is only intended as
a guide.

The maintenance system is divided into 2 main

groups:

a. Major overhaul / inspection (page 500.25):

These works are to be carried out during major
overhauls and inspections of the engine.

b. Duty during operation (page 500.26): indicated

the works to be carried out by the personnel
during the daily operation of the engine.

The stated recommended intervals are only for guid-

ance as different service conditions, the quality ofthe
fuel oil and the lubricating oil, treatment of the cooling
water, etc., will decisively influence the actual service
results and thus the intervals between necessary
overhauls.

N
F Experience with the specific plantlpersonnel should
m
9
W
be used to adjust the time between overhauls. It
0
LD
should also be used to adjust the timetable stated for -.-

G: guidance in the working cards.

F
a
2
N
"
m
0
Working Cards Fig. l instruction guide for working cards.

Each of the working cards can be divided into two: a

front page and one or several pages describing and
4 illustrating the maintenance work.

98.19 - ESO D406

MAN j.
B&W 1 ZJMD - B&W

500.24 Description
Edition 03H
Introduction to Planned Maintenance Programme Page 2 (2)

General

Experience with the specific stationJpersonnel may
lead to updating.
6) Refers to data required to carry out the work.
7) Special tools which must be used. Please note
that not all tools are standard equipment.
8) Various requisite hand tools.
9) Indicates the componentslparts which it is
advisible to replace during the maintenance
work. Please note that this is a condition for the
intervals stated.

98.19 - ESO
 Z J M D gew /Q
Description
Planned Maintenance Programme
500.25
Page 1 (3) Edition 08H

Major overhauI/inspection
Time Between Overhauls
L0 -
r I Working
Description = Ovehaultobecarriedaut Card
= Check the condition No

Cylinder Unit:

Dismantling of cylinder unit .............................................

Dismantling of cylinder head, water jacket and cyl. line:.

Cylinder Head a n d Water J a c k e t

lnspection of inlet, exhaust valves and valve guide ........

Valve rotato; ...................................................................

Lubricating of operating gear - Check .............................
Cylinder head cooling water space - Inspection ..............
Cylinder head nut - Retightening .................................... 200

Piston, C o n n e c t i n g R o d a n d Cylinder L i n e r

lnspectron of pis!on ......................................................... I

Piston ring and scraper ring ............................................ a'
Piston pin and bush for connecting rod - Check of
clearance ........................................................................ H

Connecting rod - Measuring of big-end bore ................... a

Inspection of big-end bearing shells ............................... I
Connecting rod - Retightening ........................................ 200 M

Cylinder liner - Cleaning, honing and measuring ............ •

I

C a m s h a f t a n d C a m s h a f t Drive

Camshaft - lnspection of gear wheels, bolt, connections

etc .................................................................................. 200 ¤
Camshaft bearing - Inspection of clearance ................... I
.Camshaft
. . . adjustment - check the condition .................... m . .
Lubrication of camshaft bearing - Check ........................ ¤

02.31 - ESO
L

500.25 Descript~on
Edit~on08H Planned Maintenance Programme Page 2 (3)

Major overhaullinspection
Time Between Overhauls
Working
= Overhaul to be carried out
Description = Check the condition f Card
No
0

Operating Gear f o r Inlet Valves and

Exhaust Valves

Roller guide for valve gear ..............................................

Valve gear - Valve bridge, spring, push rod, etc .............

Lubricating of operating gear - Check .............................

Crankshaft a n d Main Bearing

Inspection of main bearing ..............................................

Inspection of guide bearing .............................................

l Vibration viscodamper - see Working Card ....................

Counterweight - Retightening, see page 500.40 .............

Main and guide bearing cap - Retightening .................... 2oo

1
E n g i n e Frame a n d B a s e Frame

i
Bolts between engine frame and base frame -
Retightening, see page 500.40 ....................................... 200

T u r b o c h a r g e r System

Charging air cooler - Cleaning and inspection ................

Retightening of all bolts and connections* ......................
Cleaning of the compressor when dismounted* ..............
Cleaning of the silencer when dismounted* ....................
Basic check; all components, bearings, etc.' ..................

* see turbocharger manual

C o m p r e s s e d Air S y s t e m

Air starter motor - Dismantling and inspection ................

0406 02.31 - ESO

 ZJMD - =&W

Description
Planned Maintenance Programme
500.25
Page 3 (3) Edition 08H

Major overhaullinspection

02.31 - ESO 0406 - -v---

GENERATYUC SETS
-
 Z J M D
,G)
Description 500.26
Page 1 (2) Planned Maintenance Programme Edition 04H

Duties during Operation

1 Time Between Overhauls

00.19 - ESI 0406 --

---
S==
--
-
----
S=---
~&-=EG?E?s
 ZJMP - E&W

500.26 Planned Maintenance Programme

Description
Edition 04H Page 2 (2)

L16/24

Duties during Operation

Time Between Overhaul
-
Working
Description = Overhaul to be carried out
Card
= Check the condition

C o m p r e s s e d Air S y s t e m

Function test - Main and emergency starting valve ......... 1

, , m 513-01.40
Air filter, draining of bowl (filter element to be replaced
when pressure drop exceeds 0,7 bar) ............................ 513-01.21

Compressed air system - Check of the system .............. 513-01.90

Fuel Oil S y s t e m a n d I n j e c t i o n E q u i p m e n t

Fuel oil system - Check the system ................................ I 514-01.90

Fuel oil - Oil samples after every bunkering, see sec.504 section 504
Fuel injection valve -Adjustment of opening pressure .... 514-01. l 0
j ! l
\ : \

L u b r i c a t i n g Oil S y s t e m ' ; I 1
i 1 1 1
Lubricating oil f lter - Cleaning and replacement ............. 515-01.10
Centrifugal filter - Cleaning and replacement paper filter 0, 515-15.00

Lubricating oil - Oil samples ............................................ ¤

Lubricating oil system - Check the system ...................... H' 515-01.90

Cooling Water System

Cooling water system - Water samples ..........................

l'
Cooling water system - Check the system ...................... m, 516-01.90

Engine Frame a n d Bedplate

Flexible mounting - Check anti-vibration mountings ........ 519-03.00

Safety cover - Function test ............................................ mm11

Alternator.- see special instruction book

Major overhaullinspection, see 500.25

 Description
Operation Data & Set Points 500.30
Page 1 (3) Ed:tion 34H

L16/24

Lubricating Oil System

2ressu:e drop across fi!ter

P r e l ~ b ; i ~ t ~pressJ:e
;ig
Pressure in;e: tbro3cha;ger
5 and 6 cyl engine PI 23 1.5 k0.2 bar (C) PAL 23 0.25 bar 3 sec Yes
7, 8 and 9 cyl. er;gire 1.5 k0.2 bar
Lub. oil leve: in bass frame G?2eiLAH 26 low!high level 30 sec No
Pressure beio-e fiire- P1 21 4.5-5.5 bar
Fuel Oil System

Pressure a5er 6!te: MD0 PI40 3-6 bar PAL 40 2 bar 5 sec No
HF 0 P1 40 6-16 bar (A! PAL 4C 4-6 bar (E) 5 sec No
Leaking oi. L A Y 42 High leakage 5 sec No
level
Ternperaiurs i?let engi?? M D 0 T140 30-40°C
HFO T140 110-143'C
Cooling Water System

Press. LT system, inlet engine PI 01 1.5-L.5 oar PAL 01 0.4 + (B)bar 3 sec Yes

Press. tiT system, inlet engine PI l 0 1.5-4.0 bar PAL 10 0.4 t. (B)bar 3 sec Yes
Temp. HT system, outlet engine TI 12 76-80°C TAH 12 90' C 3 sec No
.-IAH.l2:2 - ,A3-.~.ec.-.---
,7z 3Y.C -._:,--,.. -,.
gLfjB;;'&jy
%
.. ,- -. . --, ~
, ~ ~'&cc:?'f$::.
$;;~>~~fl?j~:.~F$,t,z~+i3j$@@~~i:;+:
,-.U
~ ~ ?:. ~
:;:i,.$(q:oo*Q?.;! ,. :.,<.
",A" k
--*&--A--,>
g:.
22
j ~
;:;::.;
;.:$.-<:7.~~;,.
-%"A-->--*L.~

Temp. LT system inle! engine TI 01 1045°C

Exhaust Gas and Charge Air

Exh. gas temp. before TC T1 62 500-530" C TAH 62 600" C 10 sec No

TAH 62-2 650" C 3 sec No
Exh. gas temp. outlet c y . TI 60 425-475" C TAH 60 525" C 3 sec No
Dlff. between individual cyl. TAD 60 average + 50" C 60 sec Yes
Exh. gas temp. affer TC TI 61 325-375" C TAH 61 450" C 3 sec No
Ch. air press. after cooler P1 31 2-2.5 bar
Ch. air temp. after cooler T1 31 35-55" C
Compressed Air System

Press. inlet engine (startfstop) P1 70 7-10 bar PAL 70 6.5 bar 15 sec No
Speed Control System
. . - . .

Engine speed elec. S1 90 1200 rpm -S.%$."' 1380 rpm-*

- -.-?
. -...,-,
,--w---%--.r?- --sxL-?pY:~.

& , E ~ ~ , ~ ~ ~8F1i3~6,~m3L3;
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q~!2 :;$.~~J:~e$;~.$~:~
.$~($$a~pI$g;i&p&7>p2g!
gjpsLFJg&~~Ji!: .:~;~&$&~~.,;;
S1 90 l o O O rpm c .-._.._m
SAH 81..,-..-_e,vw
1150 rpm
,r$mSS,+;8~&.$pP.5 opm-".$
fi!;@;.~$l.3 i
~
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* ,!?::kv-n
?G:T9y$e$-
$ $ i ~ ~
2 *,. - i -

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. L
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 500.30 Operation Data & Set Points Descrrpt~on
Edrtion 34H Page 2 (3)

Normal value at full load Alarm set point and Delay Cut-off
shutdown (autostop) set point standstill

Turbocharger speed 3 sec

Alternator

Winding temperature 3 sec

Miscellaneous

Jet system failure 10 sec Yes

Monitoring system failure 120 sec. No

l Safety sysrem failure

l I 2 4 V D C i 15% I UX95-2 1 swiiil 1I 12C sec No
Turning engaged Engage; (F) 0 sec No
Local indication switzn
Remote indication sv~ikk
Common shutdown sw~:ch (F) 0 sec Yes
Monitoring sensor cable failure switch 120 sec No
Safety sensor cable failure switch 120 sec No
Start failure switzh (G) 10 sec No

Stop signal

Stop failure 30 sec Yes

Engine run SI 56 1003'<20!l r p ~
Ready to start SS 87 switch

Remarks to Individual Parameters

A. Fuel Oil Pressure, HFO-operation. C. Lub. Oil Pressure, Offset Adjustment.

When operating on HFO, the system pressure must At charge air pressure below 1.0 bar the lub. oil
be sufficient to depress any tendency to gasification pressure to turbocharger is normal at 0.6 k0.1 bar.
of the hot fuel.
The read outs of lub. oil pressure has an offset
The system pressure has to be adjusted according adjustment because of the transmitter placement. N
m
'7
to the fuel oil preheating temperature. This has to be taken into account in case of test and
W
calibration of the transmitter. e0
B. Cooling Water Pressure, Alarm Set Points. 4
.,
.'l
D. Software Created Signal. F
0
As the-system pressure in case of pump failure will
depend on the height of the expansion tank above Software created signal from PI 22, TI 12, SI 90.
z
N
m
0
0
the engine, the alarm set point has to be adjusted to
0.4 bar plus the static pressure. The static pressure
set point can be adjusted on the base module SW3.
.-
 ZJ M D - B&W

Description
Operation Data & Set Points 500.30
Page 3 (3) Edition 34H

E. Set Paints depending o n Fuel Temperature. G. Start Failure.

If remote start is activated and the engine is in

blocking or local mode or turning is engaged
Bar the alarm time delay is 2 sec.

4 7-

I
l
6 Set point curve
Start failure will be activated if revulutions are
below 50 rpm within 5 sec. from start or
revulutions are below 210 rpm 10 sec. from
start.
Start failure alarm will automatically be re-
leased after 30 sec. of activation.

H. Alarm Hysterese.
0 !
0
I
80
I
150
Temp. "C
On all alarm points (except prelub. oil pressure) a
l hysterese of 0.5% of full scale are present. On
Fig 1 Set point curva.
prelub. oil pressure alarm the hysterese is 0.2%.

I. Engine Run Signal.

F. Start Interlock. The engine run signal is activated when engine

rpm > l 130 or lube oil pressure >3.0 bar or TC
The following signals are used for start interloctd rpm >5000 rpm.
blocking: If engine rpm is above 210 rpm but below 1130
rpm within 30 sec. the engine run signal will be
l ) Turning must not be engaged activated.
2) Engine must not be running
3) "Remote" must b e activated J. Limits f o r Turbocharger Overspeed Alarm
4) N o shutdowns must be activated. (SAH 89)
5) The prelub. oil pressure must be OK, 20 min.
after stop. Eng~netype l000 rpm 1200 rpm
6 ) "Stop" signal must not be activated 5L16124 75,000 75,000
 Description 500.35
Page 1 (1) Data for Pressure and Tolerance Edition 04H

l
Section Description mm. I bar

a) Maximum inner diameter, valve guide

b) For grinding of valve spind;e and valve seat ring (see also working card 505-01.10)

c) Mnirnun height of valve head, inlet valve and exhaust valve, "H' 1

dj Miximum height of spindle above cylinder head, "H" 2

a) PISI~G
and piston ring grooves (see working card 506-01. l 0)

b) Clearance between connecting rod bush and piston pin

c) Maximum ovalness in big-end bore (without bearing)

d) Maximum inside diameter cylinder liner, max. ovalness 0.1 mm

a) Clearance between camshaft and camshaft bearing

b) Maximum clearance between camshaft and camshaft bearing

c) Clearance between teeth on intermediate wheel

a) Valve clearance, Inlet valve (cold engine 15 - 55°C)

b) Valve clearance, Exhaust valve (cold engine 15 - 55°C)

c) Maximum clearance between rocker arm bush and rocker arm shaft

a) Free spand between pick-up and band steel (Lambda controller)

98.18 - ESO D406

-
--
E
--- -
- --
- --P
U
-?
-

EEKFKTEcTE?~
 Description 500.40
Page 1 (8) Data for Tightening Torque Edition 06H

Lubricant

M Lubricating paste up to 200°C 1 Coefficient of

friction 0.08 - 0.12
Note: For tightening bolts to a specified torqe, only
use the specified lubricants. For component tem-
peratures p to 200°C, e.g. Molykote Pasta d or
1

L! I MH 1 High temperature lubricating Coefficient of Optiuoly Paste White-T. For component tempera-
l paste above 200'C ) friction 0.08 - 0.12 tures above 200°C, e.g. Moiykote Paste HSC or
Copa Slip.

XX Screw in with Loctite 243 unti! it 1

sits squarely

I Angle when slackening

i
Number of holes by which the j
1 nut must be turned back 1

Tab. l

01 screw-~n Tighten~ng Woqlng

Screw Connect~on pressure 1 moment torques Card Figure
Bar 1 torstons angle ;
I

l 012 Cylinder Crankcase

Cap main beaing /

Cylinder crankcase
' HANDhand-M
Loctite 243

012-2
Cap main bearing /
Cylinder crankcase

012-3
Crankcase /
Cylinder head

020 Crankshaft

020-1
Crankshaft / Counter 1200 45-M i
weight

020-2 ; 020-1
. .Ge.arwheel 100-M
(two parts)
1i j

020-3
Gear wheel / IOO-M
Crankshaft j 020-2
i

03.36 - ESO 0406

--
=
- - m
--_-
L_---
-
-
=
=&---~iiZcYSs
l 500.40
Edition 06H l Data for Tightening Torque Description
Page 2 (8)

-- F?->=
- -----
F ,%m
-
CSNERATbUC SETS
0406 03.36 - ESO
 Description
Page 3 (8) Data for Tightening Torque 500.40
Edition 06H

Screw Connection pressure

1 Screw-jn
moment
T~ghten~ng Please see
torques hlorkip F~gure
I torsions angle, Card

I
1 D56 Mounting of Fuel I

Crankcase covers i
Cyllnder crankcase

ID0 Control Drive

Cylinder crankcase i
Stepped spur gear

Camshafl part piece /

Bearing plate / Housing

Damper (9 cyl.) I Gear wheel

Spur gear / Bearing disk

03.36 - ESO Q406

Fr
-
= -5:- Fe=-
=
=
GENERATING SETS
1 500=40
Edition 06H i Data for Tightening Torque Descrip!ion
Page 4 (6)

-- E
- --_
- ---=X?=-
E -=_-

GENEUTING SETS
0406 03.36- ESO
 Description
Data for Tig htening Torque 500.40
Page 5 (8) Edition 06H

Plugs on the side of the fuel

Disrnouzting of purn;

289 Exhaust Pipe

Pipe piece !Compensator

Cover 1 P~pepiece

Pipe piece 1 Turbocharger

-- ---
--
E
---
-S
- P-%=
03.36 - ESO 0406 hh~Mf-~~~?E?~
 ZJMD -
500.40 Data for Tightening Torque
Description
Page 6 (8)
Edition 06H

e E
-
-
P=-
-
=
---
EEX~E~R-AT~FSC~EETS 0406 03.36 - ESO
 Descript~on
Data for Tightening Torque 500.40
Page 7 (8) Edit~on06H

l 1

l ,
Lub. Oil Cooler ,
l
I
Lub 011cooler I
i 1 5150600 ,
!

Note See also working I

card 5 15-OE 00 1

i
1

l
l
1
i
I

03.36 - ESO
 ZJMD - H&W

500.40 Data for Tightening Torque Description

Page 8 (8)
Edition 06H

Tightening of Screwed Connections by the

Torque

If screwed connections otherthan those Iiste'A are to

8 Conversion racto-r 3 47 0 75 1 40

be tightened using a torque wrench, see fah. 3.

should be looked up for approximate tightening Tab. 2. Conversionisdo;: for tisntening torques as a funct~onof
the bolt strength ~ 1 6 ~ s .
torques. The following should be observed:

- The load acting on a screwed c o n n e c ~ i ~ n

depends on the tightening torque applrec: on Approximate coefficient of friztion:
the lubricantused, the finished condition ofthe
surfaces and threads, and on the materials p = 0.08 for lubricants containing molib-
paired. It is, therefore, of great importanze that denum disulphid (MoS2)-(Molycote
all these conditions are met. pastetype G-n or HSC and Optirnoly
paste White T),
- Tab. 3 lists the tightening torques for various
threads as a function of the coefiici;n? of U = 0.14 for surfaces that are not finish-
friction p,i.e. ofthe lubricant used. The torques treated, with a thin film of oil or
are based on bolt material of the strength class grease using Lociite.
8.8 with the bolts stressed up toapproximateiy
7% of the elastic limit. For other strength
classes, the tightening torques listed in the
table have to be multiplied by thecorresponding
conversion factors. the strength class is
stamped on the bolt head.

Tightening torque in N r n Tightenme torque in Nm

Thread Coemcient of friction U Thread 1 CoeFiicient of friction p
- nominal size nominal size I
0.08 0.14

M5 4 6
M6 7 10
m8 17 25
M 10 34 53
M 12 60 85
M 14 95 . ; 135
M 14x1.5 100 145
M 16 140 205
M 16~1.5 150 220
M 18 200 280
M 18~1.5 21 5 320
M 18x2 205 300
M 20 275 400
M 20x1.5 295 450
M 20x2 285 425
M 22 370 i 540
M 22~1.5 395 595
M 22x2 380 565
I

Tab. 3. Tightening torques for bolts of the strength class 8.8.

- _=
E
_a
- _=-
E-=-
0406 03.36 - ESO
&-~-TXGF~~S
 Description
Declaration of Weight 500.45
Page I (1)
Edition 02H

Section Component Plate No Item No Weight in K g

I I

505 Cylinder head, incl. rocker arms 50501 027 85

Cooling waterjacket 50501 218 20
Cylinder unit 300

506 Piston, complete 50601 081 8

Connecting rod, complete
Cylinder liner, complete
50601
5060 1
1 068
018
20
45

509 Governor, complete 50901 021I1041

116 30

51 1 Main bearing cap 51101 157 20

Main bearing cap, axial 51101 169 21
Front-end box 51102 019 539

512 Turbocharger, complete 132

Air cooler 51201 162 450

513 Air starter 51309 242 30

514 Fuel injection pump 51401 565 15

Fuel injection valve 51402 116 5

515 Lubricating oil pump 51501 0311043 45

Prelubricating oil pump, incl. el-motor 51504 122 20
Centrifugal filter 51515 337 24

576 HT- and LT-cooling water pump 51610 105 10

00.32- ESO 0406 m---- -- --

- ----
-- I-=F-==-

GENfRATPUC SETS
Description
Ordering of Spare Parts
500.50
Page 1 (2)
Edition 01H

General

Whenever spare parts are ordered (or referred to in
correspondence, etc.) the following data must be
indicated for the engine concerned:
1) Name of Plant
These data are used by us to ensure supply of the
correct spare parts for a particular engine, even
though the spare part illustrations contained in this
bookmay not always bein completeaccordancewith
the individual components of a specific engine.

2) Engine Type and Engine no ----, built by Note: Fororderiog of spare partsforgovernor, turbo-
charger and alternator, please see the special in-
3) Illustration Plate number struction book for these components.
(complete with ed. figures)

5) Quantity Required (and description)

Information found on page 500.15 or o n the nameplate of the engine(s)

Example: Name of plant Eng. type Eng. no Built by

DANYARD 5L28132H 20433 MAN B&W Holeby

Information found or: each plate:

Plate no Edition Item no Qty. (and description)

 ZJMD - BaW

Description 500.50
Page 2 (2) Ordering of Spare Parts Edition 01H

General

Name of Plant

Engine type Engine number I Builtby

Plate no Ed. no \her- no Description Qty.

---- ----
C
E_=
I&'
-_-_- =
GEM3ATNC SETS
-
-g==---
 -
Description 500.55
Page 1 (1) Service Letters Edition 01

General

Description

In order to ensure the most efficient,economical and
up-to-date operation of our engines, we regularly
send out "Service Letters" containing first-hand in-
formation regarding accumulated service experi-
ence.
Since new service letters might be of great impor-
tance to the operation of the plant, we recommend
that engine staff file them as supplements to the
relevant chapters of this instruction book.

The service letters can either dea! with specific

engine types, or contain genera! instructions and
recommendations for all engine types, and are used
as a reference when we prepare up-dated editions of
instruction booits.

-- --- -
97.40 - ESO 0406 - ----- -
= E=-=-
CENERATRX; SETS
 Description
Conversion Table
500.60
Page I(3) Edition 01H

General
Basic SI Units Length (m)

Quanbly Name SyrnSoi 1 in (inch)

1 fi (ioo:) = 12 Inches
length metre 1 yd (yard) = 3 h = 36 ~nches 0.9144 m
mass kilogram 1 Stt!Ule mlE = 17% yCS
time second 1 n miie (lnterahola nauusal mile)
1 electric current ampere A
I
] absolute temperature' keliZln K
l1
1 amount of subs:ance mole mol SI Prefixes
lurnlnous ~n~eis'pf candeia cd
Faclor Prefix
Also nan& 'the.mmy~am;c:e,~peral;rE'

10.' deci

Supplementary SI Units 10-2 m i

10-' milli
&anti@ Name Symbol
10Z miao

l plane angle

solid angle
radian

sleradian
ra d
sr
10.!

10."

10
na-o

pim

femts

10." atto

Derived S i Units with Special Names

Quantity Name Symbol Expressed in basic,

Area (mZ)
supplementary or
derived S1 units :sq. m (s2~a:e ~ncr;) 0.6452 X lW rr?

1 S;. t (scbarefco!) 92.90 X 1OJ rr?

frequency he,* Hz 1 HZ = 1

f o e newton N 1N = 1 kg nls'
pressure, stress pas2 P2 i D2 = j ,vm2-
Volume (1 m3= 1000 1)
( energy, working oualdy o'nea: @-le J i J = :Nm
/ power wat W 1Vi' = iJls 1 1 wb. in (cub~cinch) 1 6 . 3 9 ~1 F m'

1 electnc potenbal (DC) VD!! V i V = 1W'A 1 1 cub. fl (cubic foot) 28.32 X 10.' m' = 28.32 1

tem~erature Celsius 'C 1'C = 1 k-. 1 gallon' (imperial. UK) 4.546 x 10' m' = 4.546 1

F w mechsniml sfresses Nlmm'is m d e l j used. 1 N/rni~+= :F Nlm' 1 gallon'(US) 3.785 X 10' m' = 3.785 1
1 barrel (US petroleum barrel) =
t ('Cl = T(K) - T,(K), where T, = 273.15 K
42 gallon (US) 0.1590 m'
1 bbi (dry barrel, US) 0.1156 m'

Additional SI Units I 1 register ton = 100 cub. ft 2.832 m'

* 1 gallon = 4 quarts = 8 pints
Quantity Name Symbol Definition

-
I
N
n n = mS Velocity, Speed (rnls) (3.6 kmlh = 1 rnls)
7

Q = 60 mtn
9
Sm
N
m
F
plane angle

volume
pressure
degree

Ilbe
bar bar
lI
l bar
= (rdl8O) rad

= ldm3
= 105Pa
1 kn (knot) = l nautical mildh 1.852 km! = 05144 d s

Cincem~ngother conversions, see table f w length

I
0
2
N
m
0
0

98.19 - ESO --
L '-5
- - A - -- -
---
E F C ;

GENERATNC SETS
500.60 Conversion Table Description
Edition 01 H Page 2 (3)

General

Mass (kg) Dynamic viscosity (h' s/mz)

I I I I
(
(
1 Ib (pound mass) = 16 ozs (wnces)
1 nvt (UK) (hundredweigh!) = 112 Ibs
0.4536 kg
50.80 kg
I
1
( I kp slm2
( 1 poundal sisq f:
9 8i7 N sirn2= 98.07 P (poise)
1.486 N sim'
l
1 long ton (UK) = 2 0 cwt = 2240 lbs 1.016 memc t o ~ s= 1076 kg 1 lbfisq.fi 47.88 N s/rn2
1 shwi ton (UK) = 2000 Ibs 0.997 mesic tons = 957 kg poise is a s p k - . name tanen i r o n h e CGS syslem 1 P = 0.1 Pa s
( 1 slug. 11.52 k 2 IcP=lmPas=le'?as
*
Uni! and mass in the fi-i3.s SVSIB-

Kinematic viscosity (rn2!s)

Densitv I l
1 sq.ws 92 ..
L- .
;-.: n:is = 92.90 X 1G1 CS! '
1 ib!U3 :. . - A
m c -2 kg...? = 'C1
1 cS!(cenb S~C).(E.SI .-:.S S:J~EE1s a s ~ t , aname
! &ken f;on tne

CGS sysie.;. 1 S: = 1" --'.L

Force (1 kg misZ= 1 N j
Energy, Work (1 Nm = 1 L: Wh)

1 car; . 5 4.187 J'

1 lbf ( p n d force: 4.448 N
l kpn 9.807 J
Can occasionally be found stated as kgf (kilogram force).
1 hph (metic) 26.18 X 'Cr J = 0.7355 kWh

- Standard acceleration of free fail gn = 9.80665 mls2

Una of force in the C-ibs system

In lbf

1 hph (UK, US) 2.655 X

1.356 J

1C"J = 0.7457 kWh

Imu (UK, u s ) .
. -r3, -z-X 1C2? = 1.055 KJ
Exact value: 4.1 8% J
Pressure
I.T. = Intemabx,a' S;ea- Tab'!
( l Nim2= 1 Pa: 1 bar= 105Pa, lmbar = l@'
bar)

1 @/cm2 = 1 a: = 0.9678 a;rr 98.07 x 10' Pa = C.9807 ba:

Power ( l kg mi!s3 = l N mls = lJls = 1 W)

: kpn's
1 hp (metnc) = 75 kpmis 735.5 W - 0.7355 kW

I 11nHg'F=273K: 3386 Pa = 33.86 mbar

I
1 1 in H,O- F = 277 K) 249.1 Pa = 2.491 mbar
l
1 ft lbfls

1 hp (UK, US) = 550 Klbfis 745.7

( lah(standard atmosphere)= 760 mm Hg, 1 . 0 1 3 ~10'Pa = 1013 mbar (
Ia ~ u m 0.2931 W

*
lIbflsq.in (psi)

Merwry. 1 mm Hg = 1 Torr
6895 Pa = 68.95 mbar
I
Moment of Force, Torque (kg rnz/s2= Nm)
Vaiues in table pmrided gn = 9.80665 d s l
l 1
" Water column (WC) Can easily be derived from the above tables.

Stress ( lNimz = 10 -6 Nlmmz) Moment of Inertia (kg rn2)

-
1 kp/mmz= 1W kplan2 9.807 N/mm' 1 GW (old notation) =4xI.kgmZ
1 Ibflsq in (psi) = 0.07031 at 6.895 x 1 P N/mm2 1 WR2 (old notation)' =1xl'kgm2

'l=1dmrx+ m, = massat the radius r

G=W=rnassinkg D = [)lameter ofgyration
R = Radius of gyration

98.19 - ESO
 Description 500.60
Page 3 (3) Conversion Table Edition 01 H

General

Specific fuel consumption' (glkVv'h) Some physical data in S1 units

Nomenclature
P

1 g1hph (rnetnc)
See also table for speufic fuel
1.360 glkWh
011consurnptloi values
l t = temp. in "C AK = temperature difference
p = density in kg/m3 C, = heal capacity in J!(kg AK)

Temperature difference (K)

l 1 'C (Celsius)
1 "F (Fahrenheit)
1K
519 K

Temperature levels (K) ( s e e "Dsrived SI Units with special

Names) Uscosi:!,. ' D > : C C 6 : a : LC'C
i x m- 32 = ' o a ~ =
--c
;C.''i.
:'C (Ce'slds) :.-2;5?5=K 1 ,, , E .-
.. 2 --.
;a:se2 ICY*; = 7tX m,- H j = lC13mLMr
t ' i !'ahrenhei:: 5.i:; - 32) + 273.1 5 = K Gas co,s'i,: :i?z erracs: ges =
$0. a 267 J:(ig x K)
Celsius f r o r Fa,i7enhei_ = 5'3:;. - 32, Wale. he?: 3' e;?>s~r2- ;O:'C I.C:3 bar 2.256 X IF J k g
Fue o . LOW?- ~ 3 i 5 :v2liie 4 1 4 3 X 106 J/kg
Fah.enhei:iro~ Ce!ius: ;= 9:s X + 32
$
:

I S 3 3 x 6 . '-'S55 sl;;a-; re:=-en:e be $3 X 10" J k g

( Diese en2'-e re'e.ence iua' (see b e l w )
l
Specific h e a t capacity ( J l ( k g K))
P

1 kcal.,/(kg X 'C) 4 . 1 8 7 ~1OZJi(kgK)

l BTU'/(lb X 'F) = 1 kcal,, /(kg 'C)
4.187 X 101J/(kg K) Specific f u r l oil consumption (SFOC)
British Thermal Unit (see table fw energy mversioils)

r ~ e f e r e n c econditions
S w x i c ?del D;! consumption values refer to brake power, and the f d l m i n g
Heat c o n d u c t a n c e (Wl(rn K)) re:e;eme aidi5ons

1 cai,,/(m X S X 'C) 418.7 W/(m K) 3eie;sizi wndi8ons (ISO)

1 kcal,,/(m X h X 'C) 1.163 W/(m K)
1 BTU'/(fr X h X 'F) 1.73: W/(m K) 3 ower in:e: ien,pera:ure 25'C 298 K
Brbsh Tnermal Unlt (see table for energy c n v e m m s ) 9ower inle!pressure ItKiO mba;
C7ii3s air coo!antte,nperature 25'C 298 K
cue1 oil lower cal~rif~cvalue(10200 kcalkg) 527C7 kJli:gk

Heat t r a n s m i s s i o n (W/(m2 K))

l 1 cdl,,/(mX S X 'C)
1 kcal,i(m' X h X 'C)
1 BTU'/(n2 X h X ' F

98.19 - ESO
 ZJMD -
Description
Basic Symbols for Piping 500.65
Page I(3) Edition 01 H

General

No 1 Symbol Symbol designation No 1 Symh Symbol designation

1. GENERAL CONVENTiONkL SYMBOLS 1 2.14

1

i Spectacle flange

7 1.5-
-. J~L,Cr!fice
l 1 i.1
1
1
Pipe with indication of direction of flow / 2.16 1
I
(Orifice

1 1.3 1 W 1 Valves. gatevalves, cocks and ilapr

1
1 2.17
I
it(k 1 i m p expansion joint

1.4 m Appliances 2.18. Snap coupling

1.5 01 l
Indicating and m e a s u r i ~instiuments 2.19 1 7 / Pneumatic flow or exhaust to atmosphere

' 1.6 E High-pressure pipe 3. VALVES, GATE VALVES, COCKS AND F G P S

1.7 1-
1
Tracin~ 3.1 h( Valve, straight through
I
Enclosure for several components as-
1.8 sembled in one unrt 3.2 Valve, angle

2. PIPES AND PIPE JOINTS 3.3 m Valve, three-way

2,1 1 -d-' ( Crossing pipes. not connected I I>( Non-returnvalve (flap), straight

2.2 I+I Crossing pipes, connected ) 3.5 ) fl I Non-return valve (flap), angle

/ 2.3 1 1 I Tee pipe

Non-return valve (flap), straight screw
down 1
2.4 1
l
( Flexible pipe 3.7 1 I Non-return valve (flap), angle, screw down

2.5
4- Expansion pipe (corrugated) general 3.8
& Safety valve

2.6 Joint, screwed 3.9 Angle safety valve

N
2.7 + Joint, Ranged 3.10
& Selfclosing valve
'7

&
m
:
m
2.8 --- Joint, sleeve 3.11 Quick+pening valve
2
ln
In
N

4- &
-
Joint, quick-releasing Quickclosing valve
z0 3-72

4
m
N
o
2.10 Expansion joint with gland 3.13 Regulating valve
m
0 . '.

2.1 1 Expansion pipe 3.14

& Ball valve (cock)

2.12
--(l c a p nut

2.13 -(l Blank flange 3.16 Cf3 Gate valve

97.40 - ESO -- -----

-
F-=
--
-
C L - -
p
-
--=-3-
-

QNERATWC SETS
E
- - -
 500.65 Basic Symbols for Piping Description
Edition 01 H Page 2 (3)

General

3.1 7 Double-seated changeover valve 4. CONTROL AYD REGULATION PARTS

3.18 Suction valve chest

3.1 9
l
//
Suction valve chest with non-return valves 4.2 Remote control, (
l
3.20 / &,/ -
Double-seated changeover valve, straight 4.3 1 ?! l
Spri-ig
-

) 61
I l l

3 21 Double-seakedchangeover valve, angle 44 - L I Mass

l

1 1 m1 I I
1 1

3 22 Cock straight through 4.5

l
rc ~ l o a t
3.23
l
Cock, angle 4.6 1 E
I 1 !
Pistor

3.24 / Cock, three-way, L-port in plug 4.7

0
1
l
l
I Mernvane
l
3.25
@ Cock, three-way, T-port in plug 4.8 - Electric motor

3.26
8 -
@ 1 Cock four-way. straight through in plug ( 4.9 / M- - 1 Eiectronagnetic

/ / c/
v

3.27 Cockwrth bottom connection 1 4 1 I Manual (at pneumatic valves)

3.29

3.30
@ Cock. angle, with bottom connection

Cock, three-way. with bottom connection

4.12

4.13 6
-
-l
7- Spring

Solenoid

3.31 Thermostatic valve 4.14 6

- Solenoid and pilot directional valve
p-

- -
3.32 Valve with test flange 4.15 By plunger or tracer
@C
&
.

3.33 1 %I T-7
3-way valve with remote control (actuator) 1 5 APPLIANCES
N

1 1
I 7

3.34 0- Non-return valve (air)

3.35 1 1 312 sp.ng return valve. normally closed ( 5.2 ) ) Filter or strainer

3.36 1 -11131 212 spfing return valve, normally closed 1 53 / I MagneUcfilter

1 3.37 / 1 312 spring return valve contr. by solenoid 1 5.4 / l separator

3.38 Reducing valve (adjustable) 5.5 Steam trap

3.39 m Onloff valve controlled by solenoid and pilo

directional valve and with spring return 5.6 Centnrugal pump

97.40 - ESO
 Description
Basic Symbols for Piping 500.65
Page 3 (3) Edition 01H

General

I I
No. Symbol / Symboldesignatio" / No. 1
l
Symbol Symbol designation

5.7 B Gear or screw pump 6. FITTINGS

5.8 Hand pump (bucket) 61 Funnel 1 waste tray

1 5.9 R Ejector 6.2 1 , 1 Drain

5 10 1 E
&
! 1 Var~ouraccessor~es(text to be added) 63 -- )Wastetray

5 11 I 1-
- ?IS!O? ~ J I T o
54 1 Waste tray with plug

1
I

5 12
L
heat excha~se-
1
6.5 g Turbocharger

5.13 j R ! Electric prehraar

1 1 6.6 @ Fuel oil pump

/ 5.15 ( Air filter with manual control 6.8

l
( Waterjacket

5.16 Air filter with automatic drain 6.9 1

1 - l
Overspeed device

Water trap with manual control 7. READING INSTR. WITH ORDINARY DESIGNATIONS

1 5.19 1 -D 1 silencer
1 7.2 / I Observation glass

520 ) Fixed capacity pneumatic motor with

direction offlow 7.3
5, Level indicator

5.21 1
l
ti!?i!+ Single acting cylinder with r p k g returned 7.4 I Distance level indicator

5.22 6 Double acting cylinder with spring returned 7.5 Recorder

N
F
5.23
0 Steam trap

97.40 - ESO 0406 --

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5
- p
---- - - - -

GENERATNG S f T S
 MAN
ZJMD --(B&"\

'Operatrng 562 .OX (?33k-;) I

l
loperating 502.51 (0sj-i:)
/ o u t of service 52:.as QO~K-:) l

Starting-up after repair 52I.IG j03H)

l
'Gu~del~ries
for l o ~ g t e r mloiv-load operat~onon HFO 5Cl.25 (G2H)
1
l
:~pe:ating a aiesel engine at lo\v frequency 5 ~ 1 . 2 fj( j ~ g + j
 f MAN
ZJMD - B&W % E&W%
-
Description 501.OI
Page 1 (3) Operation Edition 03H

P r e p a r a t i o n s for S t a r t i n g 4) Checkpre. lub.oilpressure at inlettofilter, inlet

of the engine and inlet turbocharger on the
The following describes what to do before starting monitoring box display according to the data
when the engine has been out of service for a period and setpoints sheet.
of time.

C o o l i n g Water S y s t e m
L u b r i c a t i n g Oil S y s t e m
5) Open the cooling water supply.
1) Check the oil level in the base frame with the
dipstick. 6) Check the cooling water pressure

2) Check the oil level in the governor, see Fig. 2, Note: To avoid shock effects owing to large ternpera-
with the level indicator on the governor. ture fluctuations just after start, it is recommended:

3) Start up the prelubricating pump
Note: The engine must b e prelubncated for at least
30 minufesprior to start-up (at the first starting-up,. or
ifthe engine is cold, the engine must beprelubricated
for at leasf 60 minutes)
or
check that there is oil coming out at bearings, pistons
and rocker arms.
a) to preheat the engine. Cooling water at least
60'C should be circulated through the frame
and cylinder head for at least 2 hours before
start:
- by means of cooling water from engines which
are running or by means of a preheater (if
installed).

L I
Fig. I Monitoring of temperaturelpressure (MTP). Fig. 2 Governor.

= ==S=

02.49 - ESO 0406 ==F

C E E W T I N G SETS
i MAN '"1
E ssw i ZJMD - E&W

501.O1 Description
Edition 03H
Operation Page 2 ( 3 )

L1 6/24
b) When starting without preheated cooling 1
water, the engine may only be started on MDO
(Marine Diesel Oil).

Note: When starting on HFO (Heavy Fuel Oil), only

item a) applies.

HFO System

7) Open the fuel oil supply

Starting on HFO: circulate preheated fuel through the

pumps until correctworking temperatures have been
achieved. This normally takes 30-60 minutes.

8) Regulating gear - please check:

- that all fuel injection pumps are set at index"0"

when the regulating shaft is in STOP position.

- that each fuel injection pump can be pressed

by hand to full index when the regulating shaft
are in STOP position, and that the pumps
return automatically to the "0" index when the
hand is removed.
Fig. 3 Operation box (OB).

Starting Air System

Check the following on fhe monitoring box according
9) Check the pressurein thestarting airreceiver(s). to the data and setpoints sheet.

10) Drain the starting air system. 14) Check the lubricating oil pressure.

11) Open the starting air supply. 15) Check the cooling water pressure.

12) Check the air pressure on the operating box 16) Check the fuel o ~feed
l pressure.
according to the data and setpoints sheet.
N
17) Check that the turbocharger is running. T-

m
0
U

Starting 18) Check that the prelubricating oil pump stops

automatically. N
In
I
13) Start the engine by activating the start button 2
Y

on the operation box; push the button until the

engine ignites, see Fig. 3.
19) Check that all cylinders are firing, see exhaust
gas temperatures.
2
a
m
0

Note: Check the stop cylinder (Lambda controller)

Testing during Running for regulating the shaft works properly, both when
stopping normally and at overspeed and shut down.
See Description 509.05 before operating the control
panel.

-
= === ===-c

CENEXATYUGSETS
- 02.49 - ESO
 ZJMD - B&W

Description
Page 3 (3) Operation
1 501.01
( Edition 03H

Checkthat all shutdowns are connected and function 29) To ensure full operational reliability, the condi-
satisfactory. tion of the engine should be continuously ob-
served so that order for preventive mainte-
20) Test the overspeed, see Working Card nance work can be carried out before serious
509-01.05. breakdowns occur, see also section 502.

2?) Check that all alarms are connected.

Stopping

Operation 30) Before stopping, it is recommended to run the

The engine should not be run up to more than 50%
load to begin with, and the increase to 100% should
take place gradually over 5 to l 0 minutes.
Note: When the engine is runningtheplannedmainte-
nance programme and the following should be
checked:
22) The lubricating oil pressure must be within the
stated limits and may not fall below the stated
minimum pressure. The paperfilter cartridges
must be replaced before the pressure drop
across the f~lterreaches the stated maximum
value, or the pressure after the filter has fallen
below the stated minimum value. Dirty filter
cartridges cannot be cleaned for re-use.
engine at reduced load, max. 2 min.
31) The engine is stopped by activating the stop
button on the operating box. Please note that
the push button must be activated at least 3
sec. before stop will be activated.
Starting and Stopping o n HFO
Starting and stopping ofthe engine should take place
on HFO in order to prevent any incompatibility prob-
lems on changeover to MDO.
MD0 should only be used in connection with mainte-
nance work on the engine or before a longer period
of engine standstill.

23) The lubricating oil temperature must be kept Before starting on HFO the engine must be properly
within the stated limits indicated on the data preheatedasdescribed in "PreparationsforStartingV
and setpoints sheet. and as described below.

24) The fuel oil pressure must be kept at the stated Stopping the engine on HFO is no problem, but it
value. should be ensured that the temperature of fuel pipes
is not reduced to a level below the pour point of the
25) The cylinder cooling water temperature must fuel. Otherwise reestablishing the circulation might
be kept within the limits indicated on the data cause problems.
and setpoints sheet.
N
m
7
0 26) The exhaust gases should be free of visible Starting o n M D 0
m
3 smoke at all loads. For normal exhaust tem-
m
N
m peratures, see the test report from shop and For starting on MD0 there are no restrictions except
F sea trials.
D that lubricating oil viscosity may not be higher than
2
N
0
1500 cSt (10°C SAE 40).
,m 27) Keep the charging air pressure and tempera-
ture under control. For normal values, see the Initial ignition may be difficult if the engine and ambi-
test report from shop and sea trials. ent temperatures are lower than 5°C and 15°C cool-
ing water temperature.
28) Recharge the starting air receivers to the de-
scribed value.

02.49 - ESO
 Description 501 .O1
Page 1 (4) Operation Edition 08H

L16/24 L27138
V28132S L21131
Preparations for Starting V28132S

The following describes what to do before starting Note: The engine must be prelubricated for at least
when the engine has been out of service for a period 5 minutes prior to start-up
of time. or
check that there is oil coming out at bearings, pistons
and rocker arms
Lubricating Oil System

I)Check the oil level in the base frame with the
dipstick.
2) Check the oil level in the governor, see Fig 2 ,
with the level indicator on the governor.
3) Start up the prelubricating pump.
L1 6/24, L27138, L21 131
Note: The engine must be prelubricated for at least
30minutespriortostarf-up (atthe firststarting-up, or
ifthe engine is cola, the engine must be prelubricated
for at least 60 minutes)
or
check that there is oilcoming out at bearings, pistons
and rocker arms.

Manuel

Fig Monitoring of ternperaturelpressure (MTP). Fig 2 Governor.

02.49 - ESO 0406

-
L
--
-
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-==
-- -- -
-h

~&=KTKc?E?s
--
 501.Ol Description
Operation Page 2 ( 4 )
Edition 08H

4) Check prelubricatinq oil pressure at inlet to

filter, inl'et of the engine and inlet turbocharger
on the monitoring box display according to the
data and setpoints sheet.

C o o l i n g Water System

5) Open the cooling water supply.

6) Check the cooling water pressure.

Note:To avoid shockeffects owing to largetempera-

ture fluctuations just after start, it is recommended,

a) to preheat the engine. Cooling water at least

60°C should be circulated through the frame
and cylinder head for at least 2 hours before
start:

- by means of cooling water from engines which

are running or by means of a preheater (if
installed).

b) When starting without preheated cooling

water, the engine may only be started on MDO
Opwatjon box iOBi
(Marine Diesel Oil).

Note: When starting on HFO (Heavy Fuel Oil), only Starting A i r System
item a) applies.
9) Check the pressure in the starting air
receiver(s).
HFO System
10) Drain the starting air system.
7) Open the fuel oil supply.
lI ) Open the starting air supply.
Starting on HFO: circulate preheated fuel through
the pumps until correct working temperatures have 12) Check the air pressure on the operating box
N
been achieved. This normally takes 30-60 minutes. according to the data and setpoints sheet. 7
m
0

8) Regulating gear - please check: .

i
m
In
0

T u r n i n g of Engine (not valid for L76124 2

- that all fuel injection pumps are set at index "0" engine) 4
o
when the regulating shaft is in STOP position. m
0
N

13) ..Open.the indicator valves and turn the engine

- that each fuel injection pump can be pressed some few revolutions, check that no liquid is
by hand to full indexwhen the regulating shaft flowing out from any indicator valves during
are in STOP position, and that the pumps the turning.
return automaticallyto the "0" index when the
hand is removed.
-

--
- - ---
W=-
=

~-TKc~E?s
0406 02.49 - ESO
 [ MAN 'it
B&W 2

Description 501.O1
Page 3 (4) Operation Edition 08H

14) Slow turning must always be carried out, be- 23) Test the overspeed, see Working Card
fore the engine is started after prolonged out 509-01.05.
of-service-periods and after overhauls, which
may involve a risk of liquid having collected in 24) Check that all alarms are connected.
the cylinders.

15) Close the indicator valves. Operation

The engine should not be run up to more than 50%

Starting
16) Start the engine by activating the start button
on the operation box; push the button until the
engine ignites, see Fig 3.
Note: I f the engine have been withoutprelubrication
for more than 20 min. it will not be possible to
start the engine (either remote or local). The
only possibility in this case is to activate the
emergencystart, located directlyon the starter.
Testing during Running
See Description 509.05 before operating the control
panel.
Check the following on the monitoring box according
to the data and setpoints sheet.
17) Check the lubricating oil pressure.
load to begin w~th,and the increase to 100% should
take place gradually over 5 to 10 minutes.
Note: When the engine is running the planned
maintenance programme and the following should
be checked:
25) The lubricating oil pressure must be within the
stated limits and may not fall below the stated
minimum pressure. The paper filter cartridges
must be replaced before the pressure drop
across the filter reaches the stated maximum
value, or the pressure after the filter has fallen
below the stated minimum value. Dirty filter
cartridges cannot be cleaned for re-use.
26) The lubricating oil temperature must be kept
within the stated limits indicated on the data
and setpoints sheet.
27) The fuel oil pressure must be kept at the stated
value.

18) Check the cooling water pressure. 28) The cylinder cooling water temperature must
be kept within the limits indicated on the data
19) Check the fuel oil feed pressure. and setpoints sheet.

20) Check that the turbocharger is running. 29) The exhaust gases should be free of visible
smoke at all loads. For normal exhaust tem-
21) Check that the prelubricating oil pump stops peratures, see the test report from shop and
2 automatically. sea trials.
m
0
P
m
a 22) Check that all cylinders are firing, see exhaust 30) Keep the charging air pressure and tempera-
LD
m gas temperatures.
. ture under control. For normal values, see the
N
I
n test report from shop and sea trials.
Note: Check the stop cylinder (Lambda controller)
0
g for regulating the shaft works properly, both when 31) Recharge the starting air receivers to the de-
stopping normally and at overspeed and shut down. scribed value.

Check that all shutdowns are connected and func-
tion satisfactory.
32) To ensure full operational reliability, the condi-
tion of the engine should be continuously ob-
served so that order for preventive mainte-
nance work can be carried out before serious
breakdowns occur, see also section 502.

02.49 - ESO _-
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W---

CWERATVUCSETS
-
 ZJMD
-
501.01
Edition 08H
Operation
Stopping
33) Before stopping, it is recommended to run the
engine at reduced load, max. 2 min.
34) The engine is stopped by activating the stop
button on the operating box. Please note that
the push button must be activated at least 3
sec. before stop will be activsted.
35) On the governor can be found a manuel erner-
gency stop botton. This can be used in case of
no pilot voltage supply.
Starting and Stopping on HFO
Starting and stopping of the engine should take
place on HFO in order to prevent any incompatibility
problems on changeover to MDO.
M D 0 should only be used in connection with main-
tenance work on the engine or before a longer period
of engine standstill.
- B&W
Description
Page 4 (4)
Before starting on HFO the engine must be properly
preheated as described in "Preparations for Start-
ing" and as described below.
Stopping the engine on HFO is no problem, but it
should be ensured that the temperature of fuel pipes
is not reduced to a level below the pour point of the
fuel. Otherwise reestablishing the circulation might
cause problems.
Starting on M D 0
For starting on M D 0 there are no restrictions except
that lubricating oil viscosity may not be higher than
1500 cSt ( l OcC SAE 40).
Initial ignition may be difficult if the engine and
ambient temperatures are lower than 5°C and 15°C
cooling water temperature.
02.49 - ESO
 Description
Page 1 (2) Out of Service
S t a n d - b y Mode
During engine standstill in stand-by position the
media cooling water and fuel 011should be conti-
nuously circulated at temperatures similar to the
operating conditions.
The prelubricating pump must always run in stand-
by mode.
Maintenance during Standstill
In periods during standstill of the engine (not in
stand-by position) it is recommended to start the
prelubricating oil pump for minimum 20 minutes
once every week and to turn the engine during the
prelubricating period b y 2-3 revolutions.
L a i d - u p Vessels
During the lay-up period we recommend that our
special instructions for preservation of the engines
are followed.
W o r k b e f o r e Major R e p a i r s
Follow all Working Cards carefully. Carry out all the
measuring and inspection stated on these Working
Cards.
l) After stopping the engine, while the oil is still
warm, start the el-driven prelub. pump, open
up the crankcase and camshaft housings and
check that the oil is flowing freely from all
bearings.
N
-W.
s
.
3
After overhaul of pistons, bearings, etc. this check
should be repeated before starting the engine.
LD
N
LD
F
o 2) Open up all filters to check that filter elements
N
are intact. Filter cartridges in the lub. oil filter
0
W
0 are to be replaced before start, after repair, or
afler excessive differential pressure. After re-
moval, dirty elements can be examined for
particles of bearing metal at the bottom of the
paper lamella (the elements cannot be used
again).
-
02.47 ESO
501.05
Edition 05H
3) A lubricating oil sample should be sent to a
laboratory for immediate analysis.
4) The installed drain fasilities in the exhaust gas
system must be open.
W o r k d u r i n g Repairs
The following should be carried out during major
repairs.
5) Retighten all bolts and nuts in the crankcase.
6) Check the various gearwheel drives for the
camshafts.
7) Remedy leakages of water and oil in the en-
gine! and blowthrough blocked-up drain pipes.
8; Drain start ng air pipes of water.
9) Empty the oil sump of lubricating oil and check
the bottom of the oil sump for fragments of
babbitt from bearings. Remove the sludge, if
not done within a period of one year. Clean the
sump very thoroughly and subsequently coat
with clean lubricating oil.
W o r k after Repairs
Cleaning of L u b r i c a t i n g Oil S y s t e m
10) If opening-up the engine or lubricating oil sys-
tem has caused the ingress of impurities, clean-
ing should be carried out very carefully before
starting the engine.
The differential pressure across the lubricating oil
filter must be watched very carefully after cleaning
and starting-up the engine. B e sure to replace filter
cartridges in due time.
11) Afterrestoring normalprelubricating oil circula-
tion, turn the engine at least two revolutions by
means of the turning device to check the
movability of the relevant parts of the engine.
12) Close drain cocks in the exhaust gas system if
mounted.
-
--
===
-v---
- ---
e==*
L-
U -
=
CENERATW SETS
501.05
Edition 05H
Out of Sewice
L u b r i c a t i o n o f M a n o e u v e r i n g Gear
13) Lubricate the bearings and rod connections in
the manoeuvering gear. Move the rod connec-
tions by hand to check that the friction in
bearings and fuel inject~onpumps is suffi-
ciently low.
14) Checks to be made just before starting the
engine are described under 501.01.
Check o f Governor
Note: At start~ng-upafter an overhaul the overspeea
shutdown must be testet at correct setpo~ntafter the
following has been done:
a) Start the engine and keep it at no load.
b) Turn the speed setting on governor until the
overspeed is released. Check that it is re-
leased at correct rpm according to "Operation
data & set points", 500.30 and working card
509-01.05.
Note: If both overspeed shutdown (SSH 81) are
activated, nuts and bolts have to be retightened
before the engine is started, (Nuts and bolts accord-
ing to the colomn "Check newloverhauled parts after
- hours" in the planned maintenance program).
15) Check the governor as follows: start up the
engine and run it at the synchronous nurnberof
revolutions.
a) Speed-setting: before switching-in thealterna-
tor on the switchboard please check that the
servomotor adjusts the rpm with a suitable
quickness after actuation of the synchronizer
knob on the switchboard. The range from - 5%
to + 5% from the synchronous rpm should be
tested.
Description
Page 2 (2)
b) Adjustment speed: switch in the alternator on
the switchboard andsetthe load to about40%.
On reaching normal oil temperatures in gover-
nor and engine increase the load instantly to
about 80% (by starting a major pump or com-
pressor). This must not cause the frequency to
fall by more than some 8%, and the engine
must return to a constant no. rpm after about 3
seconds (although this rpm will be a little lower
than before owing to the speed drop of the
governor). Ifthe engine is operated in parallel
with other engines, an even sharing ofthe load
must be established within about 3 seconds. If
the governor reacts too slowly, compensating
adjustment is effected as indicated in the
governor's instruction manual (Compensating
Adjustment).
Note: It is a condition for this test that the engine and
turbocharger are in perfect operating condition, so
that possible sources of error can be eliminated
immediately.
c) Hunting: run the engine at synchronous rpm,
and without load. Provided that the governor
oil is warm, the regulating lever must not
perform any major periodical movements, and
neither must there be any variation in the
engine speed. If that is the case, repeat the
compensating adjustment according t o the
governor's instruction manual.
d) Speed drop: in case of unsatisfactory load
sharing between two or more engines this can
be rectified by increasing the speed drop ofthe
engine that is subject to the greatest load (or
by reducing the setting of the other engines).
The setting should normally not be increased be- P
6
yond the "max" value (stated below) on the scale, 9
-3
and satisfactory parallel operation can generally be U
,
obtained at settings "normal range" (stated below). 2
Setting "Default" stated below can be used in most 59
cases. m
N
0
m
0
70-90
Default
02.47 - ESO

ZJMD - B8iW
Description
Page 1 (1) Starting-up after Repair
The following enumerated checks are to be made
immediately after starting and during load increase.
Note: In the following it is assumed that the engine
has been out of service for some time due to repairs
and that checks during out of service periods have
been carried out as described in the previous chap-
ter.
When starting up after repair, the following checks
must be made, in the order stated in addition to
normal surveillance and recording.
To be Checked Immediately after Starting
1) Check that the turbocharger is running
2) Check that the lubricating oil pressure is in
order.
3) Check that all cylinders are firing (see exhaust
temperatures).
4) Check that everyting is normal for the engine
speed, fuel oil, cooling water and system oil.
5) Check by simulation of the overspeed shut-
down device that the engine stops, see work-
ing card 509-01.05.
Note: The overspeed setting should be according to
"Operation data 8 set points", 500.30.
To be Checked during Starting-up, but only
if Required after Repairs or Alterations
6) If the condition of the machinery is not well-
known, especially after repairs or alterations,
the "feel-over sequence" should always be
followed, i.e.:
02.40 - ESO
/--,*@-'-% \,
a MAN %
P
k E & W 8'
501 . l 0
Edition 03H
General
After 5-15 and 30 minutes' idle running, open the
crankcase and the camshaft housing and perform
feel-over on the surfaces of all moving parts where
friction may arise and cause undue heating.
Feel: main bearings, big-end bearings, alternator
bearings, and camshaft bearings, cylinder liners,
roller guides and gear wheels.
After the last feel-over, repeat check 1) on page
501.05, see also "Ignition in Crankcase" on page
503.04 in section 503.
After repair or renewal of cylinder liners, piston rings
or bear~ngs.allowance must be made for a running-
in period, i.e. the engine load should be increased
gradually as indicated in the tables below. The
engine output is determined on the basis of the fuel
index and the load on the electric switchboard. The
turbocharger speed gives some indication of the
engine output, but is not directly proportional to the
output throughout the service period.
Begin the starting-up sequence at a reduced engine
speed, e.g. 400 rpm, until it can be known for certain
that there are no hot spots in the engine. Then
increase the speed to the normal rpm and connect to
the switchboard and put on load.
The load increase during the starting-up sequence
may, for instance, be:
25 % load for 2 hours
50 % load for 2 hours
75 % load for 2 hours
l 0 0 % load may be put on
For loads: see the fuel pump index on the testbed
figures in section 502.
After completing the starting-up sequence, make
sure that all fuel injection pumps are set at the same
index and that the governor can cause all fuel pumps
to move to "0" index.
 Description
Page 1 (1) I Guidelines for Longterm Low-Load Operation on HFO I 501.15
Edition 02H

General

Part loadllow load operation
In certain ship operation situations the diesel-gen-
erator sets are sometimes exposed to part loadllow
load operation.
During manoeuvring all diesel-generator sets are
often started up for safety reasons, resulting in low
load conditions for all sets.
During harbour stay even one diesel-generator run-
ning could be lowloaded when hotel purposes are
the only electricity consumers.
At part loadllow ioad it is important to maintain
constant media temperatures, i.e. for cooling water,
lubricating oil and fuel oil, in order to ensure ad-
equate combustion chamber temperature and thus
complete combustion.
At loads lower than 20% MCR there is risk of timede-
pendant retardation of the engine performance con-
dition due to fouling of gas- and air channels, com-
bustion chambers and the turbocharger.
HFO-operation at loads lower than 20% MCRshould
therefore only take place within certain time limita-
tions according to the curves.
After a certain period of HFO-operation at a load
lower than 20% MCR, a change to M D 0 should take
place in order to prevent further retardation of the
engine performance condition, or the engine load
should over a period of 15 minutes be raised to 70%
MCR and maintained here fora certain period oftime
in orderto burn off the carbon deposits, thus reestab-
lishing adequate performance condition. After such
"cleanburning period" low-load operation on HFO
can be continued.
However the operator must be aware of the fact that
fouwling in the air inlet channels, if any, will not be
cleaned with high load running. Extensive low-load
running can therefore result in necessity off manual
cleaning of the inlet channels.
If special application conditions demand continuous
HFO-operation at loads lower than 20% MCR. and
occasionally performed "clean-burning" periods are
inconvenient or impossible, special equipment and
arrangements must be established.

Load %

Admissible low-load operation Necessary operat~ngperiod

(load percenffperiod) on HFO. with min. 70% load afterlow-
load operation on HFO.

Running-up period to 70%

load: approx. 15 min.

I
l
I I l l I l I I l l t
0 1 5 10 20 30 40 50 60 70 80 90 0 1 2 3
Operating period (h) Operating period (h)
Example: a) with 10% load 19 hours maximum operation on HFO admissible, then change-over to M D 0
or b) operate engine for approx. 1.2 hours with 70% rating minimum, in order to bum off residues.
Afterwards low load operation on HFO can be continued.

Fig ILow-load operation.

 Description 501.25
Page 1 (1) Operating a Diesel Engine at Low Frequency Ed~tion01 H

Description
At land-based power stationsthe diesel generator is
often connected to a common eletrical grid with more
than one power producer.
Further the diesel engine is ofen small compared to
the rest of the grid. Under these circumstances the
diesel engine cannot control the frequency of the
grid, because the other producers are dominating.
General
Therefore it is advisable to reduce the allowable max
output of the diesel generator, in case of lower
frequencylspeed.
Maximum output should be lowered with the same
percentage as the frequencyispeed drop.
If the engine is controlled by an automatic power
management system, the program of the system
should take care of this output reduction.

If the diesel engine is delivering full 100% power at
lower speed (lowerfrequency), this is equal to over-
load on theengine. Thus, ifthe engine is designed for
50 Hz at 750 rpm and the actual running conditions
are loo%, 45 Hz (675 rpm), this corresponds to 10%
overload.
Running the diesel engine at overload condition for
a long period is not recommendable, it will damage
the engine and is therefore not acceptable. Such
operating will immediately interrupt all guarantee
obligations on the engine from MAN B&W, Holeby.
In case of no automatic power management, the
output reduction must be performed manually by the
operator.
Furthermore; it is not advisable to operate the ait-
ernator at frequency lower than 6% under nominel
frequency.
The alkernator overlunder frequency protection is
normally:
f, + 6%, 5 sec delay
Below is illustrated a power curve for 50160 Hz
engines.

Frequency
Speed 60 Hz 50 Hz
engine engine

t Operating area ,
105% 63 53 Max permissible frequency

1M)% 60 50 Recommended frequency

94% 56 47 permissible frequency

l

0 I l ( l
I lI I
0 80 85 90 I 95 100 Power (%)
94

Fig 1 Power curve for 50/60 Hz engines

 Indexpage
1 (1)
I Engine Performance and Condition ( 502 1
I l
l
!Engine performance and condition '502.02/04H)
-l -
iEvaluat~onof readings regard~ngcombust~on
15G2.Q9(QZZ-E)
?conditron
icondensate amount l

/ ~ n g i n eperformance data s c z - o ~{Q3t-;>

.~~ !
1
-p---

;check of leakages from inspection holes 5 x 2 - 0 5 . ~ 3{ e i l ~ ) I

 ZJMD
Description
Page 1 (3)
Engine Performance and Condition
P e r f o r m a n c e Data a n d Engine C o n d i t i o n
During operation small changes in the engine condi-
tion take place continuously as a result of combus-
tion, including fouling of airways and gasways, for-
mation of deposits, wear, corrosion, etc. If continu-
ously recorded, these changes in the condition can
give valuable information about the operational and
maintenance condition of the engine. Continuous
observation can contribute to forming a precise and
valuable basis for evaluat~onof the optimum opera-
tion and maintenance programmes forthe individual
plant.
E n g i n e P e r f o r m a n c e Data
If abnormal or incomprehensible deviations in opera-
tion are recorded, expert assistance in the evaluation
thereof should be obtained.
We recommend taking weekly records of the most
important performance data of the engine plant.
During recording (working card 502-01.OO can be
used) the observations are to be compared continu-
ously in order to ascertain alterations at an early
stage and before these exert any appreciable influ-
ence on the operation of the plant.
As a reference condition for the performance data,
the testbed measurements of the engine or possibly
the measurements taken during the sea trial on the
delivery of the ship can be used. If considerable
deviations from the normal conditions are observed,
it will be possible, in a majority of cases, to diagnose
the cause of such deviations by means of a total
evaluation and a set of measurements, after which
possible adjustmentloverhauls can be decided on
and planned.
E v a l u a t i o n of P e r f o r m a n c e Data
Air C o o l e r
Fouling of the air side of the air cooler will manifest
itself as an increasing pressure drop, lower charge
air pressure and an increased exhaustlcharge air
temperature level (with consequential influence on
the overhaul intervals for the exhaust valves).
98.48 - ESO
- =&W
1 502.01
Edition 04H
(
An increase in charge air temperature involves a
corresponding increase in the exhaust gas tempera-
ture level by a ratio of about 1:1.5, i.e. 1°C higher
charge air temperature causes about 1.5"C higher
exhaust gas temperature.
Reduction of the charge air pressure results in a
corresponding reduction of the compression
pressure and rnax. combustion pressure.
Fuel Injection Pump
The amount of fuel injected is equivalent to the
supplied energy and is thus an expression ofthe load
and mean effective pressure of the engine. The fuel
pump index can therefore be assumed to be propor-
tional to the mean pressure. Consequently, it can be
assumed that the connected values of the pump
index are proportional to the load.
The specific fuel consumption, SFOC (measured by
weight) will, onthe whole, remain unchanged whether
the engine is operating on HFO or on MDO, when
considering the difference in calorimetric heat value.
However, when operating on HFO, the combination
of density and calorific value may result in a change
of up to 6% in the volumetric consumption at a given
load. This will result in a corresponding change in the
fuel pump index, and attention should be paid to this
when adjusting the overload preventive device of the
engine.
Abrasive particles in the fuel oil result in wear of fuel
injection pumps and fuel valve nozzles. Effective
treatment of the fuel oil in the purifier can keep the
content of abrasive particles to a minimum. Wom fuel
injection pumps will result in an increase of the index
on account of an increased loss in the pumps due to
leakage.
When evaluating operational results, a distinction is
to be made between changes which affect the whole
engine (all cylinder units) and changes which occur
in only one orafewcylinders. Deviations occuring for
afewcylindersare, as a rule, caused bymalfunction-
ing of individual components, for example a fuel
valve with a too low opening pressure, blocked
nozzle holes, wear or other defects, an inlet or
exhaust valve with wrongly adjusted clearance,
burned valve seat, etc.
502.01 Engine Performance and Condition
Edition 04H
Turbochargers
Fouling of the turbjne side of the turbocharger will, in
its first phase, manifest itself in increasing turbo-
charger revolutions on account of increased gas
velocitythrough the narrowed nozzle ring area. In the
long run, the charging air quantity will decrease on
account of the greater flow resistance through the
nozzle ring, resulting in higher wall temperatures in
the combustion chambers.
Service experience has shown that the turbine side
is exposed to increased fouling when operating on
HFO.
The rate of fouling and thereby the influence on the
operation of the engine is greatest for small turbo-
chargers where the flow openings between theguide
vanes of the nozzle ring are relatively small. Deposits
occur especially on theguide vanes ofthe nozzle ring
and on the rotor blades. In the long run, fouling will
reduce the efficiency ofthe turbocharger and thereby
also the quantityof airsupplied forthecombustion of
the engine. A reduced quantity of air will result in
higher wall temperatures in the combustion spaces
of the engine.
Fuel Valves
Assuming that the fuel oil is purified effectively and
that the engine is well-maintained, the operational
conditions for the fuel valves and the overhaul inter-
vals will not normally be altered essentially when
operating on HFO.
If, forany reason, the surface temperature of the fuel
valve nozzle is lower than the condensation tem-
perature of sulphuricacid, sulphuric acid condensate
can form and corrosion take place (cold corrosion).
The formation of sulphuric acid also depends on the
sulphur content in the fuel oil.
Normally, the fuel nozzle temperature will be higher
than the approx. 180°C at which cold corrosion starts
to occur.
Abrasive particles in the fuel oil involve heavier wear
of the fuel valve needle, seat, and fuel nozzle holes.
Therefore, abrasive particles are t o the greatest
possible extent to be removed at the purification.
Description
Page 2 ( 3 )
Exhaust Valves
The overhaul intervals for exhaust valves is one of
the key parameters when the reliability of the entire
engine is to be judged. The performance of the
exhaust valves is therefore extremely informative.
Especially under unfavourable conditions, fuel quali-
ties with a high vanadium and sodium content will
promote burning of the valve seats. Combinations of
vanadium and sodium oxides with a corrosive effect
will be formed during combilstion. This adhesive ash
may, especially in the event of increased valve tem-
peratures, form deposits on the seats. An increasing
sodium content will reduce the melting point and
thereby the adhesive temperature of the ash, which
will involve a greater risk of deposits. This condition
will be especially unfavourable when the va weight
ratio increases beyond 1:3.
The exhaust valve temperature depends on the
actual maintenance condition and the load of the
engine. With correct maintenance, the valve tem-
peratureis kept at a satisfactory low level at all loads.
The airsupplyto the engine (turbocharger/aircooler)
and the maximum pressure adjustment are key pa-
rameters in this connection.
It is important forthe functioning ofthe valves thatthe
valve seats are overhauled correctly in accordance
with our instructions.
The use of rotocaps ensures a uniform distribution of
temperature on the valves.
Air Inlet Valves
The operational conditions of the air inlet valves are
not altered substantially when using residual fuel.
-
N
m
9
*
Fuel Injection Pumps W
in
N
Assuming effective purification of the fuel oil, the 6
operation of the fuel injection pumps will not be very
0
much affected. m
D
98.48 - ESO

ZJMD - 68EW
Description
Engine Performance and Condition
Page 3 (3)
The occurrence ofincreasing abrasive wear of plunger
and barrel can be a consequence of insufficient
purification of the fuel oil, especially if a fuel which
contains residues from catalytic cracking is used.
Water in the fuel oil increases the risk of cavitation in
connection with pressure impulses occurring at the
fuel injection pump cut-off. Afuel with a high asphalt
content has deteriorating lubricating properties and
can, in extreme cases, result in sticking of the fuel
injection pump plungers.
Engine R o o m Ventilation, Exhaust S y s t e m
Good ventilation of the engine room and suitable
location of the fresh air intake on the deck are
important. Sea water in the intake air might involve
corrosive attack and influence the overhaul intervals
for the exhaust valves.
98.48 - ESO
MAN
d =&W k
502.01
Edition 04H
The fresh air supply (ventilation) to the engine room
should correspond to approximately 1.5 times the air
consumption of the engines and possible boilers in
operation. Sub-pressure in the engine room will
involve an increased exhaust temperature level.
The exhaust back-pressure measured after the tur-
bochargers atfull load must not exceed 250-300 mm
water column. An increase in the exhaust back-
pressure will also cause an increased exhaust valve
temperature level. and increased fuel comsumption.
 Description Evaluation of Readings Regarding 502.02
Page 1 (1)
Combustion Condition Edition 0 2 ~

creasing: Fuel valve Decreasing air amount.

needs overhaul. Fouled turbocharger,
compression too low air filter or charge
owing to leakage of air cooler (air side).
exhaust valve or piston
ring blow-by.

See also:

Engine Performance
and Condition 502.01

98.19 - ESO 0406 -- ---

---
F ----
-- --
8&-K~F~yE?~
 l Description
Page 1 (2) I Condensate Amount 1 502.05
Edition 03H
1
General

Ambient air temperature (1 bar)

10 20 30 40 50 60 70 ('c) cL
C,
.-
L 0.1 0 L
m a
cl?

.
Y
m
-E
W
L
W 0
0.08 4 n
Q
U

m
Y v0 2
L0
.-
C
e
a
.-
L
m
0.06 .-
L

0
;;
0 C,
5. P
c
-c P
G
E
- 0.04

- -
P
C
Y

0.02
_m
3
-
cl? .a
L

m
L
a .G

Relative 0
air humidity 30 40 50 60 70 ('C)

Charge air temperature after cooler.

Air temperature in tank.

Fig. 7 Nomogram for calculation of condensate amount.

General Then normally, the air cannot absorb the same

amount of water as before.
There is always a certain amount of water in air.
When the air is saturated with aqueous vapour, the Condensation of water in the engine's charge air
humidity is said to be 100% and there is as much receiver is consequently dependent on the humidity
water in the air as it can absorb without condensing. and the temperature of the ambient air. To find out if
.-m: The amount of water in kglkg air can be found from
the diagram. The ability to absorb water depends on
condensation in the charge air receiverwill occur the
diagram can be used.
9
* the pressure and temperature of the air.
S
m
Example:
-*
ln
N

n
9 Amount of CondensationWater in the Charge Diesel engine1000 kW
m
m
O
N Air Receiver Ambient air condition:
a
air temperature 35 C
Both higher pressure and lower temperature reduce relative air humidity 90 %
the ability to absorb water. A turbocharged diesel Charge air temperature 50 C
engine takes air from outside, compresses and cools Charge air pressure 2.6 bar
the air.

---
= -_-----
---E

-v--- -
-------
CENERATlhC SETS
C -CL =
[ MAN 'l
B&W

502.05 Condensate Amount

Description
Edition 03H Page 2 (2)

General

A s a guidance, an air consumption of 8.2 kg1kWh (Le) A m o u n t o f Condensate Water in Air Tanks
at full load can be used for MAN B&W, Holeby
engines. Thevolumeofcondensate in theairtankisdetermined
by means of the curve at the bottom to the right ofthe
Solution according to diagram: diagram, representing an operating pressure of 30
bar.
Water content of air (I) 0.033 kglkg
Max. water cont. of air (11) 0.021 kglkg Example:

Amount of condensate in charge air receiver. Amount of condensate in air tank.

Volumetric capacity of tank (V) 4000 dm3

Temperature in tank (1) 40 "C=313K
Internal press. of tank (p) 30 bar
= 31 X 105 N/m2(abs.)
Draining of Condensation Water Gas constant for air (R) 287 Nm1kg.K
Ambient air temperature 35 "C
This phenomenon will occur on all turbocharged Relative air humidity 90 %
engines. For MAN B&W, Holeby 4-stroke engine, Weight of air in tank
there is no risk with a small amount of water in the
charge air receiver. But if the charge air receiver is
filled with water, there is a riskofgetting water into the
cylinder. This water have to be drained away. As
standard a valve is mounted on the charge air receiver1
cooler on the engine. This valve is to be used for Solution acc, to above diagram:
draining of the water. If there is a great amount, the
valve can be left half-open. If the amount jssmall, the Water content of air (I) 0.033 kglkg
charge air receiver can be drained periodically. Max. water cont. of air (Ill) 0.001 5 kglkg

Amount of condensate in air tank

 ZJMD - B8cW

Working Card 502-01.OO

Page 1 (1) Engine Performance Data Edition 03H

Safety precautions I Special tools

Stopped engine Plate No Item No Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Stopped lub. oil circul.

Description Hand tools

Measuring of engine performance data.

According to scheme "Performance L16/24"

Starting p o s i t i o n

Engine is ntnning.

Related p r o c e d u r e

Manpower Replacement and wearing p a r t s

Working time : % hour Plate No Item No Qty. I

Capacity l man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

99.03- ESO
 Performance L16124, L Z
MN l Plant:
Eng. type: Eng. No:
TIC type: Serial No:
Fuel type: Viscosity:
Density: Date:

Load YO
Air temp "C
Running hours
RPM llmin
TIC rpm llmin
HT temp. "C
HT press. bar
LT temp. "C
,LT press. bar
L 0 temp. "C
L 0 press. before filter bar
L 0 press. after filter , bar I

L 0 press. TIC bar

F 0 temp.
=C l
F 0 press. bar
CA temp. "C

M. after TIC "C

L1 Phase 'C
L2 Phase 'C
L3 Phase "C
Governor index
Power kW
Voltage V
Current A
Cos phi I kvAr
Crankcase press. mmWc

Exh. Index Pmax * M. Index Pmax *

"C mm bar "C mm
Cdinder 1
Cdinder 2
Cdinder 3
Cylinder 4
Cylinder 5
Cylinder 6

'for L16124 Pmax is not available.

Signature:
I
-m -- --
-- C---

I I Y - Y m
1 WM-1 WH5810102.9.20 0406 CFNRATNC SFTS
 Working Card
Check of Leakages from Inspection Holes 502-05.00
Page I(3) Edition 01H

Safety precautions I Special t o o l s

l
Stopped engine Plate no Item no Note
0 Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Stopped lub. oil circul.

Description
Check of leakages from inspection holes.

Hand tools

Starting

Related procedure

Manpower I Replacement and wearing parts

Working time : % hour Plate no Item no Qty./

Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.22 - ESO
l 502-05-00
Edition 01H l Check of Leakages from lnspection Holes Working Card
Page 2 (3)

Description

l ) Leakages from cylinder head, see fig. l.

If I
Then

Water leaks from the inspection hole The O-ring on the top of the liner has to be
replaced

Gas leaks from the inspection hole The sealing ring cylinder headlliner has to be
replaced

lnspection hole for

cooling water or
g a s leakage

Fig. 1 lnspection holes in the cylinder unit

- --
--
II='
--
- -- -- 98.22 - ESO
GEhEFSTNC SETS
 ZJMD - B8rW

Working Card
Page 3 (3) Check of Leakages from lnspection Holes 1 502-05.00
Edition D1 H
/

2) Leakages from HT cooling water pump, s e e fig. 2.

If Then

Water leaks from the inspection hole Check the rotating sealing

3) Leakages from LT cooling water pump, s e e fig. 2.

If Then
P
- Pp

Water leaks from the inspection hole Check the rotating sealing

4) Leakages from charge air cooler, s e e fig. 2.

If Then

Air leaks from the inspection holes The inner O-ring on the charge air cooler has to
be replaced

Water leaks from the inspection hole The O-ringson the cooling water connecting has
to be replaced

lnspection holes
for charge air
cooling water -
on bolh sides of
the front-end box

lnspection holes
for LT-water pump
rotating sealing

Fig. 2 Inspection holes in the front-end box

98.22 - ESO 0406 -

L '5-
-SE S
----p - =-
GENB(ATLNC SETS
 Trouble Tracing 503

l
iStart~ngfa~iures iSQ3.Ol {9s2H] I
7
-

,Faults ~nfuel oil system ,5@3.02{OSM) l

,Disturbances durrng running 1503.03(03H) !

,
/ignition in crankcase 533.atl (Cr3E)
I
7--

;Trouble shootrng guide for centrifugal by-pass f ~ l t e r% O Z . Q 5 (G263 I

r
--
-
iTrouble shoot~ngg u ~ d efor Alr Starter 523.06 (073) 1
_ _ p - _ _ _ _ _ _ --
-

?rouble shootrng for c o o l n ~water system 5 ~ 3 . 0 9( O S ~ > i

'Trouble s h o o t ~ r ~for
g lcbrlcat~ngoil cooler 5C3.10 (@:K)
Trouols s h ~ ~ ~ r l g j e ' e c : i i cfarlures
ai ,5.5:3.20 ( 5 2 E)
 ZJMD - B&W
1

Description 503.01
Page 1 (1) Starting Failures Edition 0 2 ~

General

1 Trouble Possible cause I Troubleshooting

l
Engine turns as soon as shut- Faults in electrical system Check electrical parts
off valve is opened, without
start button being activated.

Enginedoesnotturn whenstart Air pressure in starting air re- Start compressors, re-charge
button is activated. ceiver too low. air receiver.

Main valve(s) closed Open valve at receiver and

stop valve interposed in line
between receiver and engine.

Pinion does not engage with Check the air starter.

the flywheel.

Air motor runs, pinion engages Check the air motor for broken
but does not rotate. shafting, bearing orclutchjaws,
see Working Card 51 3-01.30.

Faults in electrical system. Check electrical parts.

Engine turns too slowly or
irregularly when start button is
depressed.
Worn air motor parts.
Remove and disassemble the
air motor. Examine all parts
and replace any that are worn
or damaged. Use the guide-
lines for determining unserv-
iceable parts, see Working
Card 513-01.30.

Start valve is sticking in closed

position.
Check start valve. 1
Low air pressure. Raise the air receiver pres-
sure.

.-
N

m
9
W
9
d Air starter works, but the drive
shaft does not rotate.
Clutch or drive shaft broken. Dismantle the air starter and
repair it.

0
In
I
Nn

2
2
N
0
CO
0
 Description
Faults in Fuel Oil System 503.02
Page I (2)
Edition 05H

Trouble P o s s i b l e cause Troubleshooting

Engine turns, but ignition fails. Fuel Sluggish movement of rnanoeuvering Lubricate and mobilize rod connections
pumps are not actuated. gear. in manoeuvering gear.

Check rod connec. Check thatfuel pump

indexcorresponds to "Adjustments after
trials" in testbed chart.

Safety system stop activated. Reset safety system stop.

Pistonin Lambda controller isactuated Check that piston is not sticking. Check
that pressure in cylinder is relieved.
Check that the shutdown trip is not
actuated.

Piston in Lambda controller cylinder is Check pressures and temperatures.

actuated due to stop function or fuel Check for faults in shutdown devices:
limitation. Check forfaults in fuel limitationdevices.
Check adjustment according to
Working Card 509-10.00.

Incorrect adjustment of Lambda con- Adjust setting of adjustment screw, see

troller's adjustment screw. Working card 509-10.00.

Governor setting incorrect. Adjust governor, see special instruction

manual.

Failures in governor. Checkthat governor is working properly.

For further fault location, see special
instruction manual in section 509.

( Sticking fuel pumps Dismantle and clean.

Engine turns, but no fuel is injected Fuel oil service tank empty. Pump oil into the tank.
owing to failure in fuel system.
If Then
Air in fuel pumps. Loosen hexagon
socket screw on
fuel pumps until air
disappears.
Engine runs, but does not ignite on all Air in fuel valves. lgnition fails on Vent the respective
N
cyltnders. one or more fuel valves.
m
7
9 cylinders due to
.
m
v
0
V)
air in the fuel
valves.
.
N
V)

I
D lgnition fails on Change the fuel
4
m
one or more valves and check
N
m
0 cylinders and them for sticking
0 no air bubbles spindle or broken
appear. spring. Check for
collecting oil on
piston top.

Air appears in Check stuffing box

the entire system. and sealing in the
fuel system.

Cont.

02.40 - ESO
 ZJMD - B&W

503.02 Description
Edition 05H
Faults in Fuel Oil System Page 2 (2)

Trouble Possible c a u s e Troubleshooting

Worn-out fuel pump Change fuel pumps.

If Then
Pressure before Clean fuel filter.
pumps is too low. Check that by-pass
valve for feed pump
is not open.

Pressure is still Increase the fuel

too low. oil feed pump
pressure.

Engine turns, fuel is injected, b ~ : Water in the fuel. Drain offwater and repeat venting of fuel
ignition fails pumpsby iooseningthehexagonal socket
screvi until air disappears.

Fuel valves or nozzles defective Changedefectivefuelvalves, seeworking

card 514-01.10.

If Then
compression Check intake and
during start too exhaust valve for
low. tight closing.
Check piston rings.

Timing of fuel Check fuel cam-

camshaft is shaft adjustment,
incorrect. see Working card
507-01.20.

Major alteration Adjust camshaft,

of the fuel de- see Working card
mand adjustment 507-01.20.
of the fuel pump
timing.

Oil has collected Slow turning to

on piston crown. remove oil. Locate
and change defec-
tive fuel valve.

Sluggish movement of manoeuvering Lubricate and mobilize rod connections

gear. and bearings in manoeuvring gear.

Fuel pump index to high Check rod connection in manoeuvring

gear. Check that governor is working
properly.
 Description
Page 1 ( 3 )
/ Trouble
Exhaust gas temperatures
increased on all cylinders.
1 512.
Exhaust gas temperature
increased on one cylinder.
l Exhaust gas temperature
decreases on all cylinders.
Exhaust gas temperature
decrease on one cylinder.
98.1 9 - ESO
Disturbances During Running
1 503.03
Edition 03H
1
General
1 Possible cause I Troubleshooting
i
Increasedcharging airtemperaturedue Clean air cooiers, see working card 51 2-01.00.
to ineffective air coolers.
Fouling of air and gas passages. Clean air and gas passages, see working cards in section
Insufficient cleaning of fuel oil or Check separator and fue! filters.
1 changed cornbustion characteristics.
-
Wrong naxinum combustion pres- Check camshat adjgstment, see working card
sure. 507-01.20.
Fuel vake or valve nozzle defective. Overhaul fuel valve, see working card 514-01.10.
Leaky exhaust valves. Check the valve clearance, see working card 514-01.10
or
change the leaky valve and recondition the exhaust valve,
see workrng card 505-01 .OS.
Note: This manifests itself by a rise If Then
in tne exhaust temperature and failling Stopping of the The fuel pump of the cylinder con-
oft+ecompression and maximummm- engine is not cerned should be put out of opera-
bustion pressure ofthe respective cyl- possible or tion by moving the index to stop
inder. convenient. and locking it in this position.
Blow-by = leaky combustion chamber. Check piston rings. see working card 506-01.35.
1 Blow-by means a serious danger of pistpn seizure, and
the engine must if possible be stopped and the piston in
question pulled. Leaky piston rings will normally result in
heavy excess pressure in the crankcase.
If Then
Stopping of the The fuel pump of the cylinder con-
engine is not cerned should be put out of opera-
possible or tion by moving the index to stop
convenient. and locking it in this position.
Damaged fuel pump cam. Replace camshaft section, working card 507-01 .05
Decreased charging air temperature. Check the thermostatic valve in the cooling water system,
see working card 51 6-04.00.
Spindle in fuel valve is sticking. Change and ovefiaul defective fuel valve, see working
card 514-10.00.
. .
Fuel pump plunger is sticking or leak- Change fuel pump plungerlbarrel assembly, see working
card 514-10.00.
Cont. I
503.03 Description
Edition 03H
D i s t u r b a n c e s During R u n n i n g Page 2 (3)

General

Trouble Possible cause Troubleshooting

Engine speed decreases Pressure before fuel pumps too low. fuel oil feed pump pressure to normal

check filter, see working card 514-01.15.

I Fuel valve defective F g e defectve valve, see working card 514-0110.

1 Fuel injection pump defective

Water in the fuel. Drain o f water i r o n service and setting tanks. Check fuel

Governor defective. See governor nanual

Engine stops. Shutdown for overspeed Check fuel pun?s, see working card 514-10.00
Check governor, see governor manual.
Check movement of regulating mechanism.

Shutdown for low lubricating Check pressostat, see working card 509-05.00.
oil pressure. Check lubricati~goil fil;er, see working card 515-01.10.
Check lubricating oil pump, see working card 515-01.00.

Shut-down for high lubricating Check lub. oil flow and pressure,
oil pressure. see working card 515-01.20.
Clean lubricating oil cooler, see working card 515-06.00.

Smoky exhaust Turbine speed lagging behind engine Clean turbine(s), see working card 512-15.00.
speed.

Air supply too low. Clean air cooler, see working card 512-01.00.
Clean air filter, see working card 512-35.00.
Clean compressor, see working card 512-05.05.
Clean turbine, see working card 512-15.00.

I Fuel valves or nozzles defective.

l Check fuel valves, see working card 514-01.10

Exhaust valve knocking. Adjusting screwfor valve setting loose. Inspect and replace defective parts, see working card
Push rod thrust disc damaged. 508-01 .OO.

Rising cooling water Thermostatic function Check thermostat.

temperature.
Pump defective Stop the engine and repair the pump.

1 Decreased flow
l Check valves.

if Then
The cooling water Open the test cocks (if fitted
temperature for the on the discharge from
entire engine has cylinders).
risen to 90-1 00°C.

Cont.

98.1 9 - ESO
 Description
Disturbances During Running
503.03
Page 3 (3)
Edition 03H

General

1 Trouble Possible cause Troubleshooting

I
Check whether steam has
developed.

Steam has deveioped. Stop the engine.

Leave the engine to cool while the
d~schargevalve is closed.

After 15 minutes open the dis-

charge valve a little to allow the
water to rise slowly in the cooling
jackets.

Check filling at test cocks.

Lubricating oil pressure Lubricating oil pump defective. Check lubricating oil pump, see working card515-01.00.
fails.
Filters fouled. Clean filter, see working card 515-01.10

Cooler fouled. Clean cooler, see working card 51506.00.

If Then
The lubricating oil Stop the engine: find the
pressure drops below cause of the pressure drop
the minimum stated and remedy the defect before
in the Data sheet. restarting the engine.

Note: Feel over 5-15-30 minutes after starting, and again

when full load is achieved.

98.19 - ESO
 Description
Page 1 (1) Ignition in Crankcase
Cause
During running the atmosphere in the crankcase
contains the same gases (NZ-0,-CO,) in the same
proportions as in the ambient air, but an intense
spray of oil drops is slung around everywhere. If
undue friction, and thus heating, arises between
sliding surfaces, or heat is otherwise transmitted to
the crankcase, the heated surface will cause eva-
poration of the lubricating oil splashed onto it. When
the oil vapours condense they form milky white oil
mist which can ignite. Such ignition may be caused
by the same "hot spot" that produced the oil mist. If
a large quantity of oil mist has developed before
ignition, the burning may cause considerable pres-
sure rise in the crankcase, forcing the reliefvalves to
open. In a few cases, presumably when the whole
crankcase has been filled with oil mist, a subsequent
explosion has thrown off the crankcase doors and
caused fire in the engine room.
Every precaution should therefore be taken to (A)
avoid "hot spots" and (B) discover oil mist in time.
"Hot spots" in C r a n k c a s e
Overheating of bearings is a result of inadequate or
failing lubrication, possibly caused by pollution ofthe
lubricating oil.
It is therefore important that the lubricating oil f~ltra-
tion equipment is in perfect condition. Filter cartrid-
ges may not be used again if they have been
removed from the filter. Checking of the oil condition
by analysis is recommended.
N
Oil Mist in C r a n k c a s e
cd
9
v heating should be felt over (5-15-30 minutes after
The presence of oil mist may be noted at the vent
L0
6 pipe which is usually fitted to the top of the engine
5
9
frame.
&
N 8)
m
O
0 Measures .(in case of white oil mist).
Warning: Keep away from doors and relief valves on
crankcase. Do not stay unnecessarily in doorways
near the doors of the engine room casing.
503.04
Edition 03H
-
General
1) Stop the Engine
2) Leave the engine room. Shut doors and keep
awayfrom them. Make readyfire-fighting equip-
ment.
Warning: Do not open crankcase until 10 minutes
after stopping the engine. When opening up, keep
clear of possible flames. Do not use naked light and
do not smoke.
3) Cut off starting air.
Set the control panel in "Blocking Mode" see
description 501.01.
Take off all doors on onesideofthe crankcase.
4) Locate the hot spot. Powerful lamps should be
employed at once (in explosion-proof fittings).
Feel over all sliding surfaces (bearings, liners,
pistons, roller guides, etc.).
Look for squeezed-out bearing metal and discolora-
tion by heat (blistered paint, burnt oil, heated steel).
5) Prevent further heating, preferably by making
a permanent repair. Special attention should
be paid to ensuring lubricating oil supply and
the satisfactory condition of the frictional sur-
faces involved. It is equally important to re-
place filter elements in time.
6) Start electrically driven lubricating oil pump
and check oil flow from all bearings and spray
pipes in crankcase while turning the engine
through at least two revolutions.
7) Stop and feel over. Look out for oil mist.
Especially the frictional surfaces that caused the
starting, and again when full load is obtained). Sec-
tion 501.l 0.
If it has not been possible to locate the hot spot,
step 7 should be intensified and repeated until
the cause of the oil mist has been found and
remedied. In very rare cases oil mist could be
due to "atomization" of lubricating oil by the
action of an alr jet (for instance blow-by, or
blow-by through cracked piston).
 Description
Trouble Shooting Guide for Centrifugal By-pass Filter 503.05
Page I(1)
Edition 02H

General
Tabulated beloware t h e remedial actions to be taken
if the following faults are observed:

Trouble P o s s i b l e cause Trouble shooting

Oil leakage through cover nut 1 Missing or damaged 0-ring Replace 0 ring
I (see ltem 158, Plate 51515).

1
I Sea face damaged. Replace 0 ring.
,
Excessive vibrstiors 1 R O ~ D ~ Obalanceowing
U~O~ to un-even
build-up of deposit on rotor walls
I( resul~ingfrom:
?
Missing or damaged 0 ring (see ltem Replace 0 ring
100, Plate 51515), allowing leakage.

I 0 - r i n g seat on rotor joint faces ( Replacerotorassembly. 1

I damaged

i
Rotor assembly inadequately tight- Tighten and bring to notice of maintenance
ened. staff.

Standtube incorrectly seated or Refit or replace if damaged

damaged.

I Dirt deposit not completely removed 1 Clean and bring to notice of maintenance I
I Rotor castings distorted through
maltreatment.

Rotor assembly components fitted in

Replace rotor assembly.

Follow sequencein Working card 515-15.00

wrong sequence. in section 515.

I Bushes looseorworn in tubeassembly. Fit new bearing tube assembly.

98.20 - ESO 0406 I

---
-- ---
---
=-T'~~CT~S
Description
Page I(1) Trouble Shooting Guide for Air Starter
Trouble
On pressing push-button, starter does
not respond and no air flow seems to
exist in control circuit.
On pressing push-button, starter does
not respond, although air flows through
control circuit.
Pinion revolves and advances, but
does not engage the ring gear.
Pinion revolves but does not advaice.
Pinion advances but does not revolve.
Pinion engages gearring, but will not
turn the engine.
Starter starts working upon opening the
flow valve of the feed line, although
push-button (or solenoid valve) are not
actuated.
Lack of starter power.
-
After starting the engine, pinion tries to
re-engage and hits the ring gear which
results in damage to both.
Starter motor will not stop.
Possible Cause, see working card
- Empty air receiver(s)
- Flow valvejs) close
- Control circuit blocked
- Leak in control duct
- Insufficient air pressure
- Push button stuck
- Excessive length of main air
pipework
- Ring gear andlor pinion burrs or
damage
and ring gear
- Push-rod Item 531 inoperative
- lnsuffrcient air pressure
- Splined shaft ltem 511 sticking
- Excessive length of control pipe
- Pneumatic motor inoperative
- Check valve ltem 578
- Main valve Item 557 blocked
- Rotors worn or blocked
- lnsufticient air pressure
- Main air pipework restricted or of
insufficient bore
- Incorrect connection of control pipes
(with separate solenoid- valve)
- Main valve Item 557 blocked and
open
- Main pipework choked or bore is
less than stipulated for the starter
- Insufficient air pressure
- Badly worn rotors
- Incorrect bore of main pipework
- Starting period unnecessarily long
- . Idling
...
of main valve item 557
- Main valve 557 blocked
- Check valve 578 keeps open or
does not seat properly
- Splined shaft 511 sticking
503.06
Edition 07H
L16124
Trouble S h o o t i n g
Charge receiver(s)
Open flow valve(s)
Disconnect and clean out
Repair or replace
Increase pressure in receiver
Remove and clean same
Approach push-button to starter or install a
solenoid valve near the IaHer
Clean burrs or replace if necessary
Check for distortion of ring gear
Disassemble, check, smoothen guide
diameter, clean or replace if rusted
lncrease pressure in receiver
Disassemble, clean, check spring ltem 513
and reassemble
Approach push-button to the starter or
install a solenoid valve near the latter
Disassemble, inspect rotor for foreign
matters between teeth and for possible
wear of gears.
Clean and reassemble. Replace worn parts
Disassemble, clean and reassemble
Disassemble, clean and reassemble or
replace
Disassemble, clean and reassemble or
replace rotors
Increase pressure in receiver
Check all pipework and replace if necessary
Connect control pipes as per installation
instruction.
Disassemble, clean and replace joint if
needed
Check entire pipework for correct bore and
replace if incorrect.
lncrease pressure in receiver.
Disassemble, replace and reassemble.
Chcek entire pipework for correct bore and
replace if incorrect.
Check and adjust timer (if fitted) or press
starter pushbuttoi for shoher period.
Disassemble, clean, oil and reassemble.
Disassemble, clean, oil and reassemble.
Disassemble, check for correct closing of
the ball and that plug presses the valve
against is seat.
Disassemble, clean, checkspring 513 and
reassemble.
 1MAN $: '

k B&W E

Description 503.09
Page 1 (1) Trouble Shooting for Cooling Water System Edition 03H

Genera l

Description The pump bearings are lubricated automatically with

The built-on fresh water pumps in the high and low
temperature circuits are of the centrifugal type. They
are mounted in the front end box and are driven
through the gearing.
oil from the lubricating oil system of the engine.
If the pump leaks and the shaft sealing rings are
worn, it is recommended to replace the shaft seal,
see Working card 516-02.00.

Trouble Possible cause

l
Troubleshooting
1
Oil or water flows out of the inspec-
tion holes.
Worn rotating sealing.

l See working card 502-05.00.

The pump does not work after start. / Pump draws in air at suction side I Check packings and pipes for tightness.
l
l The system is not filled-up. Check the level in the expansion tank.

Air cannot escape on delivery side Vent the system.

Leaking shaft seal. Check the shaft seal.

Pump capacity drops after normal Air leakages from shaft seal Overhaul the shaft seal
operation.
Fouled irnpeller. Clean the irnpeller.

Pump does not give maximum Suction valve not fully open, Open the suction valve.
delivery.
1 Defective seals Replace the seals.

I l Worn impeller and worn wear rings. Overhaul the pump.

Note: Running trouble with the pump, apart from

mechanical faults, is most often due to leaks in the
T-

m: suction line. It is therefore essential that all packings

9
and gaskets are in order and that they are renewed
when necessary. Even a tiny hole in the suction line
ul
F will reduce the pump capacity.
D
4

98.20 - ESO
 Description
Trouble Shooting for Lubricating Oil Cooler 503.10
Page 1 (2) Edition 01H

Trouble Shooting
It is necessaryto repla~edamagedplatesor~askets.
First examine the external conditions around the
plate heat exchanger in orderto localize the causeof
the damage. Do this very carefully.
General
Fatigue fracture will normally necessitate replacement
of all plates and gaskets as there may be a risk of
fatigue fracture in all the material.
In case of corrosion, all plates must be examined
carefully!
Concerning the work to be carried out see Working
card 515-06.00.

Visible Leakage

Trouble Possible cause /

1
TroubRrhooti~g

l
Leakage. Too high pressure Reduce the pressure to the correct work-
ing pressure, see page 500.30 "Operating
Data & Set Points".

Leakage.
(Phase 1)
/ InsufTicieni tightening Tighten up the plate heat exchanger, but
not below the minimum dimension and
never when the plate heat exchanger is
under pressure or over 40".
l

If the plate heat exchanger is still leaky.

proceed to phase 2.

I Leakage. Fouled or deformed plates. Separate the plate heat exchanger and
(Phase 2) lneiastic or deformed gaskets check if the plates are deformed or fouled.
Check that the gaskets are elastic and
non-deformed, and that the faces of the
joints are clean.
Replace deformed plates and gaskets, if
any.
Before assembling clean all plates and
gaskets very carefully.
Assemble the plate heat exchanger and
start it up again.
Note: Even tiny impurities such as sand
grains may cause leakage.

Leakage. Gaskets. Separate the plate heat exchanger.

(Even afler tightening of the plate heat Clean the plates very carefully.
exchanger to minimum dimension.) Replace the gaskets.
Assemble the plate heat exchanger and
start it up again.

Leakage.
Vhrough the drain holes of the gas-
kets.)
I Defectivegasketor badly corrodedplate Separate the plate heat exchanger.
Replace defective plates and gaskets, 'if
any.
Assemble the plate heat exchanger and
start it up again.

98.20 - ESO
 ZJMD - B&W

503.10 Description
Edition 01 H
Troubleshooting for Lubricating Oil Cooler Page 2 (2)

General

1 Non-Visible Leakage
Trouble Possible cause Troubleshooting

Reduced heat transmission andlor in-
creasing pressure drop.
Fouled plates or choked plate
channels.
Separate the plate heat exchanger and
check if the plates are fouled.
Clean the plates very carefully.
Assemble the plate heat exchanger and
start i: up again.

Leakage. Holes in plates. A sus,xcted leakage can be localized in

(The fluids get mixed.) Corrosion or fatigue fracture. the following way'
(Phase 1) Remove one of the lower pipe connec-
tions.
The-: put the opposite side under pres-
sure.
If the medium continues to run out of the
lower pipe connections after the pressure
has stabilized one or several plates are
leaking.
Close down the piate heat exchanger.
Separate the plate heat exchanger and
check the plates very carefully.
Check suspected plates with a dye pen-
etrant.
Check defective plates and gaskets.
Before assembling, clean all plates and
gaskets.
Assemble the plate heat exchanger and
check 13 find more defective plates, if any,
by putting one side under press.
Start up again.

Leakage. Holes in plates. Close down the plate heat exchanger.

(The fluids get mixed.) Corrosion or fatigue fracture. Separate the pate heat exchanger.
(Phase 2) Put all plates to dry. Suspend the plates in
the plate heat exchanger againand tighten
it.
Circulate medium at full capacity on one
plate side (every second plate channel).
Keep the other plate channels unpressu-
rised and free from liquid!
Stop the circulation after a few minutes of
operation and open the plate heat ex-
changer again. Take care to avoid water
spraying onto the dry plate side!
By a careful study of the plates it will be
possible to find moist areas, if any, on the
otherwise dry plate sides.
Check these areas with a dye penetrant!
Replace defective plates and gaskets.
.. .
Before assembling,
. . -
clean.
all .plates
. .
and
gaskets.
Assemble the plate heat exchanger and
check tofind more defective plates, if any,
by putting one side under press.
Start up again.
If the unit is still leaking, check all plates
with a dye penetrant!

98.20 - ESO
 Description
Trouble Shooting IElectrical Failures
Page 1 (6)
T r o u b l e Shooting
This description is a trouble shooting guide for the
automation system on the diesel engine type L161
24 and L27138.
General
The following trouble shooting guide is an aid in iso-
lating troubles to the engine built-on safety system
and monitoring system incl. the sensors connected
to these systems.
CAUTION! The control system can be damaged
with the wrong voltage. When replacing a control
unit, check that the power supply is switched off
during replacement and check the power supply for
the correct voltage before switching-on.
Table 1.lfor the safety system and table 1.2 for the
monitoring system are general guides for isolating
system problems. Each system check assumes that
the prior checks have been done properly. Table 1.3
and 1.4 are system error messages which can be a
guideline to the problem.
If the conclusion of a trouble shooting indicates that
an exchange of a module is needed, please fill-in
the enclosed inspection report, and return the mod-
ule together with the inspection report to the engine
maker.
Label Failure LED
Fig 1 Hardware module.
503.20
Edition 01H
Further, please remember to inform the software no
when ordering a new module.
Safety System
The safety system is an independent system and
consists of maker ABB PLC hardware modules and
MAN B&W software. Fig 1 describes the hardware
modules.
For wiring of the modules and sensors a reference
is made to the scheme which can be found in the
operation manual, section 509.
The safety system consists of two ABB PLC mod-
ules. The modules named 3P1 is the CPU module
and the module named 4P1 is an 110-module. Indi-
cation of individual input and output can be found
on the modules by yellow diodes. The reference
number for each input and output can be found in
the scheme:
On the operation box individual indication of the shut-
downs (low lub. oil pressure, high cool. watertemp.,
overspeed and emergency stop) can be found.
If a replacement module is needed, the software ver-
sion must be informed at ordering. Software version
number is written on the module.
Label ' Failure LED
1 503.20
Edition 01H 1 Trouble Shooting I Electrical Failures
Table 1.l
Trouble
Engine will not stari.
Start motor is not engaged.
All shutdown LED are alight on the
monitoring box.
Lowlub. oil shutdown occurs when
normal stop is activated.
Thealarm .System 8 Power failure'
is activated.
Diode A1O.O1 is not alight or diode
A10.02 is not alight.
. .
The shutdown functions are not
working.
Overspeed set point is not correct.
l l
Possible cause
Supply voltage polarity, or no sup-
ply voltage.
RUNISTOP changeaverswitch on
3P1 in wrong position.
NOsoftware in the module.
Output relay on A10.04 is in failure
or loose connections.
One or several shutdown signals
are activated on the monitoring box
Connectorisnot~rrectl~ connected
on internal failure in 3P1 or failure in
CPU socket.
Damaged or wrong adjustment of
the rpm pick-up.
The internal bus connection is dis-
connected or internal component
failure.
. module.must be replaced. Observe h a t no..sed
1 Wiring or sensor problem.
Internal component failure.
Missing jumper or wrong software.
l Description
Page 2 (6)
1
Troubleshooting
Check the supply voltage on the green diode on
3P1. If it is alight the power supply for the PLC
modules are OK.
Put the RUNISTO? change-ver switch in RUN
posifion. Check RUN LED on 3P1.
If all diodes on 3P1 and SP1 are alight after having
switched on the powersupply,the moduleis without
software. The mduie must be replaced with a
module incl. sofware.
Note! Afterswitch-on ofthe power supplythe initiali-
zation takes app. 3 sec. Please wait these seconds
before observation.
Check that diode A10.04 is alight.
lfA10.04 is notalightcheckthatA62.01 isalight and
A62.07 is stable (continuous on or continuous ofl)
Check for loose wires on terminals 27 + 28 on 4P1.
R e s ~+hie shutdowns.
If one is still activated on the operation box, check
that inputA62.00, A62.01, A62.02 and A62.03 are
not alight. If one is alight, check the sensor and
wiring for short circuit.
Check the connector J29 on the base module. No
red LED must be alight on 3P1 or 4P1. Activate the
change-over switch RUNISTOP. Exchange the 3P1
module.
Check the pick-up for correct adjustment.
Sensing distance= app. 1 mm, (for Honeywell pick-
up the latern must be placed at 3 or 9 o'clock)
Check tbat the connector is plugged correctly. Be
aware that no counternuts prevent from plugging
the connector correctly. Replace the pick-up.
Note! Diode A62.07 will be alight if actual speed is
above nominal speed. Ifactual speed is below, itwill
be dark.
Check that the bus connection on temlinals 1 + 2 is
OK. Check that the resistance (120R) is installed
correctly and OK. Check that power supply is OK.
(Green diode must be alight). Switch on the RUN1
STOP change-over switch. The problem could be
related to an internal component failure and the
diode is alight on 3P1 or 4Pl.
Check the wiring for shutdown sensors.
Replace the module.
Check that E62.10 is alight for 720 rpm engines.
and OFF for 750 rpm engines. Check the software
label on the front of the module or in the scheme.
 503.20 Trouble Shooting I Electrical Failures
Edibon 01 H
Table 1.2
l 1
/ Engine will not start.
Start motor is not engaged
Data communication failure.
No RPM indication
the engine suddenly starts or stops.
LED flashing greeh, yellow or red.
All red diodes on the operation box
are al~ght.
l Jet system activated under no load
condition andtorjet alarm activated.
Possible cause
Power supply is not correct, inter-
lock activated or internal cornpo-
nent failure
I EMCproblen orloose connections.
I Defect pick-up or incorrect adjust-
ment.
Two or more earth failures on the
engine and yard installation
I l
Internal component failure or EMC
problem.
No power supply or software in the
safety system.
1 The bandsteelon thelambdaarmis
adjusted incorrectly.
Description
Page 4 (6)
( Troubleshooting
*
Check that the power supply is correct 24 V 20%
on terminals J3; 132, 133.
Check that no interlocks are activated
- Turning gear not engaged
- No start faiiure astrvated
- No engine run signal
- Remote mode is activated
- No shutdown activated
- Stop valve not activated
- No lub. oil pressure
- Prelub. oil pressure is OK
Check that LED on base module is steadily green
alight. See also table 1.3
Check that wirings from terminals J20; 98,99 are
correct.
Check the safety system (see table 1.1)
Check thatthe ONlOFF switch on the base module
is working properly.
Note! After having switched on the power supply,
the system initializes app. 3 seconds. Please wait
with observations until initializing is finished.
Replace the base module.
I Check that the green LED on the base module is
alight. See also table 1.3
Check that all cable screens are connected w r -
rectly in the EMC cable glands.
Checkthatthedatacommuniation cable (MODBUS)
is the twisted pair type.
Check the pick-up for correct adjustment.
Sensing distance = app. 1 mm. (for Honeywell pick-
up the latern must be placed at 3 or 9 o'clock)
Check that the connector is plugged correctly. Be
aware that no counternuts prevent from plugging
the connector correctly.
Replace the pick-up. For the Dr. Horn pick-up the
sensing distance must be 1-1.8 mm (the thread on
the pick-up is 1 mm)
Chedc for earh falures on all sensors.
Spedal attenth should be made to the exh. gas sen-
sors. Ch& for earth falures in the yard system. R&
place the base module.
See table 1.3. Switch the power ONIOFF.
Exchange the base module.
Check the safety system accodlng to table 1.1.
Adjust the band steel to app. 2-3 mm above the jet
pick-up.
Cont.
 ZJMD - =&W
Description
Page 5 (6) Trouble Shooting I Electrical Failures
Cont. Table 1.2
Trouble Possible cause
"Frozen" operation box, MTP and Internal software failure.
MEG box.
I Instable behaviourofthe outputsig- Too high voltage on the output cir-
nals for starVstop of prelubricating cuit terminals J20, 108, 109
r
Temp. ind~cationis too high acc. to lntemal component failure.
calibrated values, orvalues are ab-
normal.
Changeaver switch between LO- lntemal failure in the operation box.
CAL-REMOTE -BLOCKING is not Damaged flat cable between print
working. card and front panel.
The alarm "System & Power failure' Thisalam consists of different alarm
is activated. possibilities
1) Power & system failure in the
safety system.
2) Power supply failure to the pres-
sure sensors.
3) Cableiwire failure for monitor
sensors.
4) Cablehire failure for safety sys-
tem sensors.
5) Communication link failure.
i 6) Tacho failure.
OB display indicates OFFLN or Cable break on data communica-
ERR-1 or fault. tion or sensor(s).
1 503.20
Edition 01 H 1
Troubleshooting
See table 1.3. Switch the power supply onioff.
Exchan3e the base module.
1 Check that the voltage is below 48 VDC.
i20 VAC o: 220 VAC is not allowed.
Note! The voltage must be checked in the
pielubricatingpump starter panel.
Replase the base module
See table 1.3 and 1.4. Replace the operation box.
1) Check diode A1O.O1 on the safety system
module4PI. If it is alight, it is OK. No red LED must
bealighton3Plor4Pl .Seealsotable 1.l.SUPPLY
LED and RUN LED must be alight.
2) Check green diode J29iJ30 and fuse 2.5 AT. If
green diode is alight, it is OK.
3) Check if any analog signals are missing: If all
signals are present, it is OK. Remember to check
also the spare exh. gas input channels. A jumper
must be present. See also table 1.4
4) Checkdiode A10.02. If it is alight, it is OK. If it is
not alight, check the safety system for cable break
or loose connections.
5) Checkif rpm pick-up is OK, andior lub. oil pres-
sure is OK. If lub. oil pressure is normal, but no rpm
signal is present, the tacho alarm will be activated.
6) Checkthediode on the base module totable 1.3
and table 1.4.
Seetabie1.3. Check cable installation for sensor(s)
andior data communication
503.20 Trouble Shooting I Electrical Failures Description
Edition 01H Page 6 (6)

Table 1.3
p

Base Module LED indications

On the Base Module printed circuit board a two-coloured lamp (light diode, LED) is located , which indicates the current state of the
Base Module central processor.

The following failure LED indications are possible:

Observations Description

GREEN permanent light OK, all lnterlink modules are online

I
GREEN flash One or more lnterlink modules are offline (disconnected']or ~ncorrec:setup on Sd2.
I
RED permanent light BM internal hardware error (or lockup caused by EMC disturbances)
I
YELLOW permanent light BM internal hardware error (or lockup caused by EMC distil-bances).
I
RED flash BM software or hardware fault The number o i flashes indicates an internal error code which must be
reported when re!uming the module. (It n a y also be caused by EMC disturbances) 1
Yellow 4xflash MODBUS address error (SW?):lncorrectiy set to an illegal address (0 or 255, all switched ON or OFF).

l Other yellow flashes BM internal software fault. The number of flashes indicates an internal error code which must be re-
poried when rerurning the module. (It may also be caused by EMC disturbances)

Table 1.4
Display indications o n the Operation Box (OB)

( Observations I Description
-
1

i lieady
OFFLN
l Shown for a few seconds when the OB module is powered on, indicating that the internal selftest of the module
was successfully passed.

The OB module is OFFLINE. There is no communicationfrom the base module to the OB module. This message
will appear shortly when powering on the system, indicating that the base rnoduie has been reset.

- Defective link between BM and 0 B module.

- No power on BM
- BM fatal hardware or software error. Indicated be red or yellow light or flashes on the BM two-coloured LED.

ERR-1 Indicates cable break or sensor failure on the corresponding input.

FAULT Indicates that the BM module has entered failsafe mode either because of a fatal software or hardware fault.

Shown if the exhaust temperature is selected for an invalid cylinder number.

 MAN B&W Diesel A/S, Holeby

Electronic Device - Inspection Report NO.:

(to be a t t x h a ' to the component in failure) (date + nohnitials, ex. 20001218-01EIF)

Type: Plant Name:

Part No.: Engine No.:
Serial No.: Engine Maker:
V)

Purchase Order No.:

Claim Report No.:
ag
'r m Periodically Constant Warranty Non-warranty
05
O i D e s c n p t l o n
0W -
+
J2
ms
L .E

Date: Signature:

Failure Type Dafective Module Defective Parts F.type Remark

Name c. Name8 No. Diagram No. Code
de
Defed Comp. A
Mming Comp. B
Reversed Comp. D
Printed Track C
Soldering E
A

Adjustment F
.-C
g klechanical G
W
Water Damage H
t
I . G
Software Update I

L Q l l I I

P" Special Repair l Exchange Price

S
- Standard Repair l Exchange Price
IS Time Hours Exch. Cost
m
- Remarks:

Assumed reason for the failure:

Design Production Installation External Influence
I Date: Repaired by: 1
 ZJMD - E&W

Specification and Treament,

Lubricating Oil, Fuel Oil and
Cooling Water
lI 504 lI
;Lubricating oil specification :sa4.aI jo5r-r) . . .
r
;Maintenance of lubricating oil condition '504.03 (CE4H)i
.....
!
k r i t e r i a for cleaning/exchange of lubricating oi! 554.94. {G331
. . -
!i
......... . . . .

jLubi-icatirig points 15gri;.as( a z f i ) !

l
. . . . . . . . . . . . . . . . . . .......... . . . . . . . . . . . . . . . . . . z

/Lubricating oil in base frame :c.?.fi

,d,,QE (08%)
I . . . . .

!specific lube oil consumption - SLOC

. . . . . . . .
P-
. . . .
p--

;504,87 (BZE)
~.
1
l
. . .... . . . . . . . . . . ........ PP-
-
. . . . .
1
[Fuel oil specification 1586.2n ( ~ 4 .% ) . . . .
. c
- . . . . . . . . . . . . . . . . . . . . . . . . . .

5EL;.Zj(azn
. ~

::Fuel oil quality

--__~-.. .-_. ........ ... ...............-. .
1$
! . . . . . . ...........
1
~ / ~ o r n o ~ r_..
2 -
P
for ... _ _ . . . of CCAI
a r ndetermination . . . . . . . . . .
i.5 ~. 4. . 2 6(OZH)
.- ...- . . . - i
;
;!~nalysisdata 15-34.27 (02s) .
:
I
I- . . . . . . . . . . . I .... ..............
i
X

2
.!Fuel oil cleaning
1 .
I
. . . . . . . . . . . . .. _ _ _ (O2.H)
1504.30
. _ ..-,-..
~
. . . I . . . . . .'!
.
l
.

l ~ r e s hwater system treatment 1504.40

. .
(02H)
. . . . . . . ~ . . !
? . .............. ...... .-. . . .
 .4
_ I.

\\\
MAN
ZJMD - B&W i
F
B&W i
+

Description
Lubricating Oil Specification 504.01
Page 1 (1) Edition 05H

General

Requirement Guiding Values

This document is valid forthe following engine types: Based on typical load profile for marine GenSet (50-
L16/24, L21131, L23/30H, L27138, L28/32H, V281 60% of rated power)
32H, V28132S
Oil type TBN TBN TBN
For the engines, a HD-lub. oil (heavy duty) corre- (initial) (equilibriurn) (min. level)
sponding to at least type CD Comercial Class D after
AFI service system (meets MIL-L-2104 C and D) has Gas oil 8-12 6-8 6
to be used.
Marine diesel 10-15 8-10 8

The oil should be rust and oxidation inhibited. Heavy fuel (Scl.5: 10-15 8-10 8

When selecting a lubricating oil, attention must be Heavy fuel (1.5cSc2.5j 75-20 10-14 8
paid to the fuel oil sulphur content.
Heavy fuel (2.5cS<3.5) 20-25 10-14 8

Due to generating running mode for HOLEBY's Heavy fuel (3.5cSc4.5) 20-25 10-14 8
engines, where the lub. oil consumption depends on
running time and the fuel oil consumption and follow-
ing the sulphur input to the lub. oil depends on the Based on typical load profile for stationary GenSets
load, a lower TBN-value (Total Base Number) than (50-100% of rated power)
normal for main engines is needed.
Oil type TBN TBN TBN
(initial) (equilibrium) (min. level)
Viscosity
Gas oil 8-1 2 6-8 6
Marine
Marine diesel 10-15 8-10 8

Engine SAE class Heavy fuel ( S 4 .S) 15-20 8-10 8

L23/30H, L+V28/32H
30* 105 mm2/secat 40" C Heavy fuel (1.5<S<2.5) 20-25 10-14 8
L16/24, L21131, L27138
Heavy fuel (2.5cSc3.5) 20-30 10-14 8
40 145 mm2/secat 40" C
Heavy fuel (3.5<S<4.5) 20-30 10-14 8
Stationary

L16/24, L21131, L27138 Based on typical load profile for variable speed
L23/30H, L+V28/32H, V28132S engine, pumps (10-100% of rated power)
N
Y

W
40 145 mm2/sec at 40" C
0 I I
T
Oil type TBN TBN TBN
m
0
*At cooling watertemperatures above 32" C SAE 40 (initial) (equilibrium) (min. level)
oil can be used. In this case, please contact MAN
B&W, Holeby. Gas oil 10-14 6-8 6
2
N
a Marine d~esel 12-16 8-10 8
g If load profile is different, this should be taken in
consideration. Heavy fuel (S<1 .S) 15-20 8-10 8

In the long run though, the operation results are the Heavy fuel (1.5<S<2.5) 20-30 10-14 8
criteria that prove which TBN is the most economical
Heavy fuel (2.5<S<3.5) 20-30 1@14 8
one for efficient engine operation.
1 Heavy fuel (3.5<S<4.5) 25-30 10-14
l
 ZJMD-
Description
Page 1 (21 Maintenance of Lubricating Oil Condition
General
During operation of trunk engines the lubricating oil
will be contaminated slowly by small particles origi-
nating from the combustion.
The burning of heavy fuels will normally increase this
contamination due to the increased content of car-
bon residues and other impurities.
C~nta~mination of lubricating oil w ~ t hwater, fresh or
salt, can also take place.
A certain amount of contaminants can be kept sus-
pended rn the lubricating oil without affecting the
lubricz:.in g properties.
But tne condition of the lubricating oil should be kept
under observation by analyzing oil samples. See
also 504.04 "Criteria for CleaningiExchange of
Lubricating Oil".
The engine bearings are protected by the full-flow
lubricating oil filter built onto the engine, the filter
cartridges having a fineness of 15 micron and the
safety filter a fineness of 60 micron.
The condition of the lubricating oil can be main-
tainedireestablished by exchanging the oil at fixed
intervals or based on analysis results.
O p e r a t i o n o n M a r i n e D i e s e l O i l (MDO)
The buik-on full-flow dept filter cleans the oil thor-
oughly. For operation on M D 0 we recommend to
insta!l a built-on centrifugal by-pass filter too.
O p e r a t i o n o n H e a v y F u e l O i l (HFO)
For engines operating o n HFO a lub. oil centrifugal
unit is required.
Continuous lub. oil centrifugation plus a built-on full-
flow depth filter clean the oil in a sufficient and safe
way. Any other filter system is not necessary, but not
wasted.
02.16- ESO - G
m
BM
p
(,G , -X-.>,
i'M A NU,
& B&W 1
504.03
*,.
Edition 04H
General
A more economical solution is to maintain the condi-
tion by continuoustreatment. Experience has proved
that centrifuging is superior to other methods of
cleaning lubricating oils.
The optimum cleaning effect is achieved by keeping
the lubricating oil in a state of low viscosityfora long
period in the centrifuge bowl.
Low viscosity is obtained by preheating the lubricat-
ing oil to a temperature of 85°C - 95°C.
Slow passage of the lubricating oil through the
centrifugal separator is obtained by using a reduced
flow rate and by operating the separator 24 hours a
day, stopping only when cleaning of the bowl is
necessary.
When treating detergent type lubricating oil, the flow
rate is usually recommended to be reduced to 15-
25% of the rated flow of the separator.
In order to keep the amount of lubricating 011in the
engine in good condition, it is necessary to treat 0.3-
0.4 likw per hour.
A centrifuge fortreating this amount of lubricating oil
under the aforementioned derated flow conditions
should havea rated capacityof 1.5-2.5 likw per hour,
but in each case the separator manufacturer's rec-
ommendations for capacity and operating in-
structions should be followed.
For engines with cartridge-type oil filters (depth
filters), continuous and efficient purification of the oil
in the separator is essential to ensure a long service
life for the cartridge filters.
For cleaning of the lubricating oil system after over-
hauls and inspection of the lubricating oil piping
system, see section 515.
Deterioration of O i l
Oil seldom loses its ability to lubricate, i.e. to form a
friction-decreasing oil film, but it may become cor-
rosive to the steel journals of the bearings in such a
way that the surface of these journals becomes too
rough and wipes the bearing surface.
l
504.03
Edition 04H
Maintenance of Lubricating Oil Condition
General
In that case not only must the bearings be renewed,
but the journals must also be polished. The corro-
siveness of the lubricating oil is either due to far
advanced oxidation of the oil itself (TAN) or to the
presence of inorganic acids (SAN). In both cases the
presence of water will multiply the effect, especially
an influx of sea water as the chloride ions act as an
inorganic acid.
Oxidation o f Oils
At normal service temperature the rate of oxidation
is insignificant, but the following factors will accele-
rate the process:
H i g h Temperature
If the coolers are ineffective the temperature level
will generally rise.
A hightemperaturewill also arise in electrical preheat-
ers if circulation is not continued for 5 minutes after
the heating has been stopped, or if the heater is only
partly filled with oil.
Catalytic A c t i o n
Oxidation of the oil will be accelerated considerably
if catalytic particles are present in the oil. Wear
particles of copper are especially harmful, but also
ferrous particles and rust are active. Furthermore,
the lacquer and varnish-like oxidation products of
the oil itself have an accelerating effect. Continuous
cleaning of the oil is therefore important to keep the
sludge content low.
Signs of Deterioration
If circulating oil of inferior quality is used and the
oxidative influence becomes grave, prompt action is
necessaryas the last stages in the deterioration may
develop surprisingly quickly, i.e. within one or two
weeks. Even if this seldom happens, it js wise to be
acquainted with the signs of deterioration.
Description
Page 2 (2)
These may be some or all of the following:
- Sludge precipitation in purifier multiplies.
- Smell of oil becomes acrid or pungent.
- Machined surfaces in crankcase become cof-
fee brown with a thin layer of lacquer.
- Paint in crankcase peels off or blisters.
- Excessive carbon is formed in the piston cool-
ing chamber.
In a grave case of oil deterioration, the system
should be cleaned thoroughly and refilled with new
oil.
Water Washing
Water washing of HD oils must not be carried out.
Water in the Oil
If the TAN is low, a minor increase in the fresh water
content ofthe oil is not immediately detrimentalwhile
the engine is running. Naturally, it should be brought
down again as quickly as possible (below 0.2%
water content, which is permissible). If the engine is
stopped while corrosion conditions are unsatisfac-
tory it should be turned just over 112 revolution once
every hour (i.e. stop in different positions) while the
oil circulation and purifying at a high preheating
temperature continue to remove water. Water in the
oil may be noted by steam formation on the sight
glasses, by appearance, or ascertained by immers-
ing a piece of glass ora soldering iron heated to 200- F
m'
300°C in an oil sample. If there is a hissing sound, 9
P
water is present. If a large quantity of water has
entered the oil system, it may be profitable to suck up :
I,
sedimentedwater from the bottom of the tank. Taste a
thewater for salt. If salty, an oil sample should be 2m
0
analysed immediately for chloride ions. m
a
02.16 - ESO - G
 Description
Criteria for CleaninglExchange of Lubricating Oil 504.04
Page 1 (2) Edition 03H

Replacement o f L u b r i c a t i n g Oil 3. Water Content

It is not possible to predict the expected life time for Limit value : < 0.5
lubricating oil, as it is not possible for the engine preferred 0.2 (higher value is
manufacturer to know which fuel and lubricating oil permissible in a shorter period)
qualities will be used and under which operation
conditions the engine will be operated. Possible test
method : Patable test unit or gas chrom-
A replacement of lubricating oil is required when the atography (or infra red distil).
oil's identification values have changed no that the If the limit value is exceeded, a
lubricating cleaning and neutralization properties no supplementary test for chlorides
longer are sufficient. (ASTM D-878) can be made.

Exchange of the lub. oil has to be based on the oil

suppliers evaluation of sampies of oil in service. 4. T o t a l Base N u m b e r (TBN-Number)
Samples should be forwarded at appropriate inter-
vals at least once every three months depending of Limit value : Ref. to fresh-oil TBNYo : > 70%
running-mode and results of last analysis.
Unit : mg KOHlg
The oil sample should be taken after the filter and, if
possible, while the engine is running as this will Possible test
ensure that the test will be representative for the method : ASTM 0-2896
whole change in the engine.
Due to the generating running mode for HOLE-
BY'S engines, where the lub. oil consumption
Evaluation o f the L u b r i c a t i n g Oil C o n d i t i o n depends on running time and the fuel oil con-
sumption and following the sulphur input to the
For evaluating the conditions of a used oil, the lub. oil depends on the load, a lower TBN-value
following guidance conditions are iionaliy suffi- than normal for main engines is needed.
cient. Anyway, all parameters have to be evaluated
as a whole, and no single can be taken as a criterion Following guiding values can be given:
for changing oil.
Oil type TB N TBN (equi-
(initial) librium)
l.V i s c o s i t y
Gas oil
Limit value : < +l viscosity grade
Marine diesel
Heavy fuel ( S 2 . 5 )
Units : SAE-units
Heavy fuel (S>4)
Possible test
method : ASTNl D-445 (modified) The TBN is normally reduced gradually with the
time of operation. The influential elements are the
sulphur content in the fuel oil, the lubricating oil
-
2. Flash P o i n t amount and the amount of re-filling due to normal
6
'
N
consumption. After a certain time of ope-ration,
m
0
O Limit value : > 185" C the TBN will stabilize at a lower value, the TBN
equilibrium.
Possible test
method : Setaflash tests (cut of point cor
relates with 204" C i ASTM D-92
(cot)
 ZJMD - B&W

504.04 Criteria for CleaninglExchange of Lubricating Oil

Description
Edition 03H Page 2 (2)

General

Re-filling should be carried out with lubricating oil of Unit : Weight %

the initial TBN.
Possible test
method : ASTM D-893 procedure B in n-
5. Neutralization N u m b e r Heptane.

Limit value : 0.4-1.0 above typical level Additionally

test : If the level in n-Heptane insolub-
Unit : mg KOHig les is considered high for the ty-
pe of oil and application, the test
Possible test could be followed by a supple-
method : ASTM D-974 mentary determination in Tolu-
ene.

6. T h e T o t a l C o n t a m i n a t i o n ( i n s o l u b l e s Con- Also infra red test can be used.

tent) Heptane insolubles

Limit value : < 1.5 generally, depending upon

actual dispersant value and the
increase in viscosity.
 Description 504.05
Page 1 (1) Lubricating Points Edition 03H

General

Lubricating Oil Types Used in the Engine

Description Lub. Oil Type

Engine system lubricating oil SAE 40 oil according to lubricating oil specification on page 504.01.

Turbocharger Engine system lubricating oil

Governor See governor instructions in section 509

Alternator See special instructions in section 518 or separate instructions

Hydraulic tools / Hydraulic oil or turbine 011 (with a viscosity of about SAE 20).

97.40 - ESO 0406

---
L
-
-----
-
e s c
W -

CWERATNG SETS
- -
E=---
=--
- - M

-
 Description
Page 1 (1) Lubricating Oil in Base Frame
1 504.06
Edition OSH 1

Type L 16/24 5 cyl. 6 cyl. 7 cyl. 8 cyl. 9 cyl.

Min. level alarm H1 (mm) 285 285 285 285 285

Min. level H2 (mm) 295 295 295 295 295

Max. level H3 (mm) 370 370 37 0 370 370

Max. level alarm H4 (mm) 385 385 385 385 385

Min. litre (H2) 342 389 436 483 530

Max. l~tre(H3) 42 9 488 547 606 665

99.27 - ES1 0406 --- - - - -

---
--
=.===,=
c--
(IENERPITNC
----m
--==
-=
SETS
 Description
Page 1 (2) Specific Lube Oil Consumption SLOC
In order to determine the engine condition, the lube
oil consumption needs to be recorded. To secure a
uniform method to evaluate the SLOC, the following
method should be used as guidance:
During the routinely engine inspections the lube oil
level in the base frame must be observed. The
engine must be in operation or the pre-lubricating
pump must be running during this inspection!
The lubeoil volume between maximum and minimum
level at the dipstick is described in the Instruction
Manual or in the Product Manual. If the lubeoil level
is atthe minimum, lube oil is added until themaxlevel
is reached at the di~stick.
The lube oil volume added, the lube oil temperature
and the engine running hours are recorded and the
readings could be filled in the attached data sheet.
The lube oil density, p @ 15°C must be known in
order to convert p to the present lube oil temperature
in the base frame. The following formula is used to
calculate p:
P
,, Q,,., [kg/m31- 0364 * ,U,,
,,, ,["Cl - 15)
The following formula is used to calculate theSLOC:
SLOC [g/kWh] =
(lube oil added - A I - A2 T d m - ~ p i U b e o i , ~ ~Note *)
run.hrs period * P,,& [ k W
03.14 - ESO
504.07
Edition 01H
General
In order to evaluate the correct engine SLOC, the
following circumstances must be noticed and
subtracted from the engine SLOC:
A I ) Desludging interval and sludge amount from
the lube oil separator (or automatic lube oil filters).
The expected lube oil content of the sludge amount
is 30%.
The following does also have an influence on the
SLOC and must be considered in the SLOC
evaluation:
A21
Lube oil evaporation
Lube oil leakages
Lube oil losses at lube oil filter exchange
The engine maximum continuous rating (P,,,) must
always be used in order to be able to compare the
individual measurements, and the running hours
since the last lube 011adding must be used in the
calculation. Due to inaccuracy *) at adding lube oil,
the SLOC can only be evaluated after 1,000 running
hours or more, where only the average values of a
number of lube oil addings are representative.
If the SLOC deviates from the nominal value stated
in the lnstruction Manual or in the Product Manual,
the engine cylinder condition should be inspected.
Adeviation of? 1 mm with the dipstickmeasurement
must be expected, witch corresponds k 5 dm3,
depending on the engine type.
- ----- -
--
--
= =c
-
= ---
p
F--?;=-=
-
W R A T N C SETS
- - -
 Description 504.07
Page 2 (2) , Specific Lube Oil Consumption SLOC Edition 01H

General

Plant I Ship .
Lube oil consumption
i
]Engine type:- Engine # : I
Lube oil brandltype:

Density @l
5°C: [kg/rn3]
Date / Run. hrs I Add.Lube oil AI + A2 ) L.O.Temperature 1 SLOG l~emarks
[h] 1 [dm3] ["C] [g/kWh] 1

03.14 - ESO
 [-MAN 'f$
ZJMD - =&W E B&W a

Description
Fuel Oil Specification 504.20
Page 1 (3) Edition 04H

General

Commercially available fuel oils with a viscosity up to The data refer to the fuel as supplied, i.e. before
700 cSt at 50" C corresponding to 55 cSt at 100" C any on-board cleaning.
can be used for MAN B&W Holeby4-stroke medium
speed diesel engines.

For guidance on purchase, reference is made to I S 0 1 Property Units Value

8216/17, BS 6843 and to CIMAC recommendations l

regarding requirements for heavy fuel for diesel Density at 15°C kglm3
engines, third edition 1990. From these maximum
accepted gradesare RMH 55 and K55. The mention- Kinematic
ed I S 0 and BS standards supersedes BS MA 100 in viscosity
which the limit is M9. at100°C cst
at 50 "C cst
It means that engines can be operated on the same
fuel oils as MAN B&W 2-stroke low-speed diesel 1 Flash point "C
engines.

The data in the above HFO standards and specifica-

1, Pour point "C

tions refer to the same fuel type as delivered to the Carbon residue % (mlm)
ship, i.e. before on-board cleaning.
1 Ash % (mlrn)
In order to ensure effective and sufficient cleaning of
the HFO, i.e. removal ofwater and solid contaminants, Total sediment
the fuel oil specific gravity at 15" C (60" F) should be after ageing % (mlm)
below 0.991. Higher densities can be allowed if
special treatment systems are installed. % (vlv)

Current analysis information is not sufficient for Sulphur YO (mlm)

estimating the combustion properties of the oil.
This means that service results depend on oil pro- Vanadium mglkg
perties which cannot be known beforehand. This
especially applies to the tendency of the oil to form Aluminium +
deposits in combustion chambers, gas passages Silicium mg/kg
and turbines. It may, therefore, be necessary to rule
out some oils that cause difficulties.
mlm = mass V N = volume

Guiding Heavy Fuel Oil Specification ) May be increased to 1.010 provided adequate
cleaning equipment is installed, and modern
Based on our general service experience we have, type of centrifuges.
N
7 as a supplementto the above-mentioned standards,
W
4 drawn upthe guiding HFO-specificationshown below.
m
-J
S
ln
If heavy fuel oils, with analysis data exceeding the
N
m Heavy fuel oils limited b y this specification have, to above figures, are to be used, especially with regard
5 the extent of the commercial availability, been used to viscosity and specific gravity, the engine builder
z
0
with satisfactory results on MAN B&W GenSets. should be contacted for advice regarding possible
m
m changes in the fuel oil system.
 ZJMD - E&W

504.20 Fuel Oil Specification Description

Edition 04H Page 2 (3)

General

Fuel Oil Condition, when Entering the Engine

As practically all fuel oil specifications including the
above standards refer to the same fuel type as
supplied, the fuel supplied to a ship has to be treated
on board before use. For running on the oil quality
mentioned above it is necessary that equipment
exists on board, which can treat, viz clean and
preheat, the fuel oil with optimum efficiency.
In B 11 00 0 "Cleaning Recommendations" our
recommendations are outlined.
For economical HFO operation the fuel oil condition
at engine inlet should be as recommended below.
For fuels above 180 cStl5O0 C a pressurerized fuel
oil system is necessary to avoid boiling and foaming
of the fuel.
The viscosity leaving the heaters should be 10-15
cSt and approx. 12-18 cSt entering the engine. The
maximum temperature of oil after preheater should
be 150" C to avoid to rapid fouling of preheater.
The preheating chart on page 3 ~llustratestheexpect-
ed preheating temperature as function of the specific
fuel oil viscosity.

Property Units Max. value

Water ?hby volume max. 0.2

Solid
particles ppm (mglkg) rnax. 20

Particle size Micron max. 5

Viscosity CSt Range 12-18

 a;""'
p:
L,
#~a3iP-=k~:*j

g MAN '1
ZJMD - B&W
= & W "L

Description
Page 3 (3) Fuel Oil Specification 1 504.20
Edition 04H
/
General

-
Fuel oil preheating chart

Approx. viscosity
after preheater

Temperature
after preheater 'C

Log scales 10 15 25 35 45 1 55 cSti100" C

30 60 100 180 380 700 cSti5O0C

200 400 800 l500 3500 7000 sec. RwI100" F

Viscosity of fuel

U
4
This chart is based on information from oil suppliers regarding typical marine fuels with viscosity index 70-80.
0
Since the viscosity after the preheater is the controlling parameter, the preheating temperature may vary,
dependent on the viscosity and viscosity index of the fuel.

01.34 - ES1 0406 ---

--
- -- ---
- -----
- ---
-
===P-- -
-
CENERATNC SETS
 Description
Page 1 ( 2 ) Fuel Oil Quality
General Considerations
The quality of a fuel oil is stated, in analysis data, in
terms of physical and chemical properties,which are
decisive to the suitability of the fuel oil for different
applications. For diesel engine fuels the combustion
quality, the content of impurities and the handling
properties are the main quality criteria.
Since residual fuels are traded and designated
according to viscosity, it has become common
practice to associate viscosity with quality. This
practice can be very misleading, especially with
modern residual fuels, as a fuel oil of low viscosity
can often be just as bad, or even worse, than other
fuel oils of very high viscosity.
The quality of refinery residues is dependent on the
origin of the crude oil, the grade of utilization when
refining the crude oil, and the refinery technique
used.
Some of the residues used in fuel oil production are
of a viscosity requiring visbreaking, a process which
will reduce the viscosity without improving the quality
at all.
When producing residual fuels from visbreaked,
cracked residues and from "straight run" residues,
the final adjustment of viscosity to fulfil the
requirements of the different grades of intermediate
fuels is achieved by adding gas oil.
However, it must benoted that considerablereduction
of the viscosity is achieved by adding a relatively
small amount of gas oil, which will give only a minor
improvement of the quality of the blend. This means
that the qualityto a major extent depends on residues
present in the blend. Therefore the quality also
depends on the density, see 504.26.
As a consequence of the possible variations in the
quality of residues and the influence of adding gas
oil, the quality of blended fuels can vary, even for fuel
oils of equal nominal viscosity.
02.16 - ESO- G 0406
504.25
Edition 02H
General
Combustion Quality
Combustionqualityis the abilityof the fuel oil toignite
and burn in a proper way. The ignition quality,
combustion intensity, and length and completeness
of combustion are properties influenced by the
chemical combustion and structure of the fuel oil.
Ignition quality relates to ignition delay, i.e. the time
elapsed betweenthe start of injection and the start of
combustion.
Ignition quality is expressed by the cetane number,
diesel index or cetane index. In all cases the higher
the value: the betterthe ignition quality. For diesel oil
the ignition qualityisexpressed bythe cetane number
determined by a specified method in a standard
engine running under standard conditions.
Forresidualfuels the ignition quality can be expressed
by the diesel index or cetane index, both to be
calculated from physical properties such as the
aniline point, specific gravity and mid-distillation
temperature. The cetane number, diesel index or
cetane index ofa certain fuel oil will show reasonable
correlation between the numerical values.
A FIA cetane number test is also good for evaluation
of the combustion quality.
The combustion condition of the fuel oils is normally
evaluated from Conradson Carbon residue and the
asphaltene contents.
Content of Impurities
The content of impurities of diesel engine fuels
should be kept as low as possible, and harmful and
unwanted impurities should, to the greatest possible
extent, be removed in the pre-treatment system in
order to minimize wear and corrosion of engine
components. Impurities derive from the crude oil
itself, from refinery processes and from handling and
storage of oils. Someimpurities, such as sulphurand
vanadium, are oil soluble and therefore impossible
to remove i n a conventional mechanical fuel oil
treatment system, while the amount of water and
solid impurities can be reduced by centrifuging and
filtration.
-
----- --
--- --
- - ---
-----
- - - - - L & -
-
m m----
p
GENERATNO SETS
-
504.25 Fuel Oil Quality
Description
Edition 02H Page 2 (2)

Genera l

Sand, rust, metal oxides and catalyst particles can
be found as solid particles in fuel 011.
Fuel-related wear and corrosion in diesel engines
take the form of mechanical wear and chemically
induced corrosion, the latter in the form of high and
low temperature corrosion.
The solid impurities and particles produced during
combustion, collectively known as ash, cause
mechanical wear of engine components.
Especially catalyst particles, silicone and aluminium
oxides and silicates in the form of sand are very
abrasive. From vanadium and sodium corrosive ash
in the form of oxides, carbonates and sulphates, is
created during combustion.
The flash point-is related to the volatility of the
amount and nature of lighter fractions in the fuel oil,
and might thus be used to estimate the propensity of
gasification in non-pressurized parts of the fuel
system
The pour point defines the temperature at which wax
crystallization will take place and prevent the fuel oil
from flowing and from being pumped
Therefore, the pour point must be taken intoaccount
when deciding the presence and capacity of heating
coils in bunker tanks.
Qualiiy Fuel Oil Main Effects
Criteria Characteristics

The sulphur content of a fuel oil may lead to low

temperature corrosion of combustion chamber Fouling of gasways.
components and the formation of deposits on these.
The corrosive effect is duetothe formationofsulphuric Sulphur Corrosive wear. Cold
acid. corrosion.

Vanadium Formation of deposits on

Water in the fuel oil may lead to several detrimental Sodium exhaust valves and turbo-
effects to the fuel system and to the diesel engine in chargers.
general by giving rise to mechanical and corrosive
wear, as well as fouling.
Water Disturbance of combustion
process.
Increased heat-load of corn-
Handling Properties Content of bustion chamber compo-
impurities nents, fouling of gas ways.
mechanical wear and cavita
Handling of the fuel, i.e. storage, pumping and
tion of fuel injection system.
treatment, is affected mainly by physical properties
such as viscosity, density, flash point and pour point, Ash Mechanical and corrosive
but other fuel oil properties such as stability, emul- wear of combustion
sification tendency, viscosity index and the nature chamber components.
Formation of deposits.
and amount of water and solid impurities will also
Catalyst fines Mechanical wear of fuel in-
influence the handling system. jection system, cylinder
liners and piston rings.
The nominal viscosity is decisive for the preheating m
temperature necessary toachieve adequateviscosity Viscosity Temperatures, pressures,
Density and capacities of fuel oil
2
for pumping, settling, centrifuging and injection. g
Handling Pour point systems for storage, m
m
N
properties F
The density influences the gravitational settling of D

water and solid contaminants in settling tanks. 2N

m
0
Specific gravity isalso an important parameter in the 0

centrifuging process. The flash point is, for safety Table I. Fuelproperties affecting diesel engine and fuel systems.
reasons, limited to a minimum of 60°C (140°F) by
classification societies and other authorities.
 Descript~on
Page I(2) Nornogram for Determination of CCA! 504.26
Edition 0 2 ~

General

CCA l

Normal
operating condition
I
Difficulties
may be
encountered

Increased difficulties
up to engine
damage after
a short time

Legend

V Viscosity, mm2/s (cSt) at 50°C.

D Density, kg/m3 at 15°C.
CCAl Calculated Carbon Arornaticity Index.

Fig 1 Nomogram for determination of CCAI.

01.34 - ES1 0406 ---

E 1-C
-- --
-----
- - - m - -

GENERATING SETS
504.26 Description
Edition 02H Nomogram for Determination of CCAl Page 2 ( 2 )

General

Example: Ignition quality is an important fuel parameter. The

Viscosity: 180 cSt at 50°C
Density: 990 kg/rn3at 15°C
The combining straight line across density (990 kg/
m3)and viscosity (180 cSt) of a heavy fuel oil results
in CCAl (859). From CCAI, conclusions may be
derived with regard to the ignition qual~ties.
CCAl may be calculated with the aid of the following
formula:
CCAl = D - 141 log (log (v + 0.85)) - 81
reason why it does not appear in the international
specifications isthat there are no standardized testing
method is non-existent. Therefore, parameters such
as the Calculated Carbon Aromaticity lndex (CCAI)
are resorted to as an aid which is derived from
determinable fuel parameters. According to our
experience, only a rough assessment of the ignition
quality of the heavy fuel oil is possible with the help
of this method.
However, the CCAl has become so well-known in
widespread publications that, in spite of the
reservations mentioned above. We were compelled
to classify the respective MAN B8W Diesel N S ,
Holeby engines according to CCAl-rating, too.
 Description
Page I(4) Analysis Data
C o m m e n t s o n A n a l y s i s Data f o r F u e l Oils
C a r b o n Residue
The carbon residue of a fuel oil indicates its coke-
forming tendency and can be used to determine the
tendency to form deposits in the combustion cham-
ber and gasways. The higher the carbon residue
value, the higher the fouling tendency.
Some changes in the combustion process, requiring
adjustment of the maximum pressure, may also be
attributed to a high carbon residue content. The
value is measured by standardized tests, such as
the Conradson or Ramsbottom tests which give
similar results.
The non-vaporized residue from the carbonizing test
consists of carbonaceous material and inorganic
impurities and is expressed as percentage weight of
the fuel sample tested. Carbon residue and
asphaltenes content generally move in parallel, both
in relation to the carbon-to-hydrogen ratio, with in-
creasing values for a higher ratio.
The carbon-to-hydrogen ratio and thus also the
carbon residue depends on the source of the crude
oil and the type of refinery processing used.
The effect of carbon residue is impossible to coun-
teract by pre-treatment of the fuel oil, as centrifuging
only influences solid inorganic contaminants and
hard asphalts, which are only small amounts of the
percentage weight called carbon residue.
Asphaltenes
1
Asphaltenes is defined as the part of a fuel oilsample
whlch is insoluble in heptane. The content of
N
asphalteness is expressed as percentage weight of
0
the fuel o ~sample
l tested.
l %?
0
m
N
Asphaltenes, which is aromatic, slow-burning, semi-
l
solid hydrocarbon compounds dispersed in the fuel
Z
0
oil, has a similar effect on the combustion process to
B the carbon residue, the main impact being fouling of
gasways. The stability of the fuel oil is related to the
asphaltenes content.
02.16 - ESO - G
504.27
Edition 02H
General
Asphaltenes also influences the lubricating proper-
ties of the fuel oil and, in extreme cases, high
asphalteness content may lead to fuel injection
pump sticking.
Fuel oils with a high asphalteness content will have
a tendency to form sludge, especially if the water
content is also high. The asphaltenes content of a
fuel oil is influenced by pre-treatment. The heaviest
semi-solid asphaltenes, and asphaltenes bound to
water as sludge, can be separated by centrifuging.
Diesel Index
Diesel index is a calculated value to determine the
ignition quality of a fuel oil. The ignition quality is
related to the hydrocarbon composition, paraffin
being of high quality, n-heptanesof moderate quality
and aromatics of low quality.
With certain exceptions the properties of the aniline
point and the specificgravity reflect the hydrocarbon
composition of a fuel oil, and are therefore used in
the following simple formula as an expression of
ignition quality:
Diesel index = (aniline point "F X API gravity) X 0.01.
The aniline point is the lowest temperature at which
equal volumes of the fuel and aniline become just
miscible. The test relies on the fact that aromatic
hydrocarbons mix completely with aniline at com-
paratively low temperatures, whereas paraffins re-
quire considerably higher temperatures before they
are completely miscible.
A high aniline point thus indicates a highly paraffinic
fuel, and consequently a fuel oil of good ignition
quality. Similarly, a high API gravity number denotes
a low specific gravity and high paraffinicity, and
again a good ignition quality.
The diesel index provides a reasonable idea of the
ignition quality, but generally gives figures slightly
above the cetane number.
Fuel oils with poor ignition quality and a low diesel
index might in particular cause problems in starting
diesel engines and running at low load.
 ZJMD
1 504.27
Edition 02H
1 Analysis Data
General
In addition to starting difficulties, a prolonged ignition
delay may give rise to alternations in the maximum
pressure, leading to increased mechanical or ther-
mal load.
Furthermore, fuel oils with poor ignition quality may
cause retarded combustion and subsequent fouling
of gasways.
Sulphur
Sulphur is present in fuel oil, mainly as organic
compounds, the amount present being expressed
as percentage weight of an oil sample tested. If free
sulphur is present it may cause corrosion in the fuel
system. The main problem caused by sulphur is low
temperature corrosion. During combustion, sulphur
oxides are produced in the form of gases. Since
humidity is also present sulphur and sulphuric acid
may be formed on components in the combustion
chamber and in thegasways, wherethe temperature
is below that of the dew point for sulphuric acid.
The detrimental effect of sulphur in fuel oil is counter-
acted by maintaining an adequate temperature of
the combustion chamber components and by using
alkaline lubricating oil to neutralize the sulphuric acid
produced during corn bustion.
Vanadium a n d S o d i u m
Vanadium and sodium are constituents of the ash
content. The amounts of these are measured by
analyzing the residue from the combustion test used
for determination of the ash content. The amount of
vanadium and sodium present is expressed in ppm,
parts per million, by weight in relation to the fuel oil
sample being tested for ash content. Vanadium
derives from the crude oil itselfand, being oil soluble,
cannot be removed from the fuel oil by conventional
pre-treatment. Sodium derives from the crude oil,
and also from contamination with salt water during
storage and transport of the fuel oil. Sodium is water-
soluble and, regardless of derivation, tends to com-
bine with the water present in the fuel oil.
Owing to its water solubility, it is possible to remove
or reduce the amount of sodium present in the fuel
oil. During combustion, corrosive ash is formed from
vanadium and sodium.
- E&W
Description
Page 2 (4)
Especially if the weight ratio of sodium to vanadium
exceeds 1:3, ash with a very low melting point and
stiction temperature is formed, giving rise to high
temperature corrosion of exhaust valves and de-
posit formation in turbochargers.
It is possible to reduce the tendency for formation of
detrimental vanadium-sodium ash by effective cen-
trifuging, which will remove sodium salts together
with water. Ifa very low content ofsodium is ensured,
a relatively high vanadium content might be accept-
able.
Water
The water content of fuel oil is measured by a
standardized distillation test and is expressed as
percentage volume of the sample tested. Water in
the fuel oil may lead to several detrimental effects on
the fuel oil system, and corrosion and cavitation of
fuel injection pumps and fuel valves, and cause
fouling of exhaust systems and turbochargers.
Due to its content of sodium, salt water in combina-
tion with vanadium contributes to the formation of
low-melting corrosive ash, which attacks exhaust
valves and turbochargers. When it disturbs the fuel
atomization, water will lead to poor combustion,
resulting in higher heat load on the combustion
chamber components.
It is possible to reduce the water content of a fuel oil
primarily by centrifuging, and this should be done to
the widest possible extent in order to avoid the
detrimental effects of water in the fuel oil.
Ash
Ash content is a measure of the non-combustible
material present in the fuel oil. The ash content is
determined by a combustion test and it is expressed
as a percentage weight residue from complete com-
bustion of the oil sample tested.
Ash-forming materials are present in the fuel oil as
natural components of crude oil and due to external
contamination of the fuel oil.
02.16 - ESO - G
 ZJMD - B&W
Description
Page 3 (4) Analysis Data
Ash-forming materials exist both as solid contami-
nants and in soluble compounds. The solid contami-
nants may lead to abrasive wear in the fuel injection
system. Ash formed during combustion may lead to
abrasive as well as corrosive wear of combustion
chamber components and give rise to formation of
detrimental deposits. It is therefore essential, to the
greatest possible extent, to reduce the amount of
ash-forming materials by centrifuging.
Solid contaminants such as sand, rust, certain metal
oxides and catalyst fines can be removed by centri-
fuging, and the same goes for water-soluble salts
such as sodium.
Some ofthe components included in the ash content
have been found to be particularly harmful and are
therefore stated individually in the analysis data.
Silicium and Aluminium Oxides
Residual fuels produced b y refineries using fluid
catalytic cracking may b e contaminated by catalyst
particles in the form of silicium and aluminium ox-
ides. Any catalyst particles are shown by the ash
l content value. Separate values for silicium oxide
content and aluminium oxide content are measured
1 by analyzing the ash content.
.- The amount of sllicium and aluminium oxides is
expressed in ppm in relation to the weight of the
original fuel oil sample being tested for ash content
As catalyst particles are very hard and abrasive, they
can cause extreme mechanical wear of the fuel
injection system, cylinder liners and piston rings.
Catalyst particles, being solid and insoluble, can be
removed from the fuel oil. The guidelines for
2 dimensioning the centrifuge size are based on the
W As the formula indicates, the API gravity is in inverse
I
,"
a
fact that approx. 113 of the catalyst particles in terms
0
V) of weight is removed.
N
V)
F Densityis an important parameter in the centrifuging
I A-
Viscosity
0
m
0
Basically viscosity is a measure of the internal fric-
tion or resistance of a liquid to flow.
02.16 - ESO - G
504.27
Edition 02H
General
Viscosity of Marine Gas Oil (MGO) and Marine
Diesel Oil (MDO) are expressed in centistokes (cSt)
at 40" C.
Viscosity is an important parameter in connection
with pumping, pre-treatment and injection of fuel oil,
sincethe possibilityand efficiencyofthese processes
to a large extent depend on adequate viscosity.
Adjustment ofviscosi:yto adequate values is possible
by taking advantageofthe interdependence between
the temperature and viscosity index of the fuel oil.
The nominal viscosity of a fuel oil is the factor
determining the preheating temperatures necessary
to obtain adequate viscosity for pumping, centrifug-
ing and injection of the fuel oil, and thus also the
factor determining the capacity of the preheating
equipment in the fuel oil system.
Density
Density is defined as the mass of a unit volume and
is expressed in g/cm3 at a temperature of 15°C
(59°F).
Specific gravity is the ratio of the mass of a given
volume of liquid at 60°F (1 56°C) and the mass of an
equal volume of water at the same temperature. For
a given liquid, the specific gravity will generally give
the same numerical value as the density.
API gravity is an arbitrary scale calibrated in degrees
and related to specific gravity by the following for-
mula:
141.5
+ 131.5
gravity = specific gravity/50°F
proportion to density and specific gravity.
process, where separating water and water-dis-
solved impurities from the fuel oil is based on the
difference in densities. If the density of the fuel oil
approaches that ofwater, centrifuging thus becomes
less effective, necessitating a reduced flow rate and
therefore increased centrifuge capacity.
504.27 Description
Edition 02H
Analysis Data Page 4 (4)

General

The water separation ability of fuel oil is increased by Pour Point

preheating the fuel oil prior to centrifuging since the
densities of fuel oil and water change with the
temperature at different rates, thus making it possi-
ble to optimize density differences.
To some extent the quality of a fuel oil can be judged
by the density, since this is directly proportional to
the carbon-to-hydrogen ratio, which again is in direct
proportion to arornativity, carbon residue and
asphaltene content, but in reverse ratio to calorific
value.
Analysis Data for Fuel Oils
The pour point is the lowest temperature at which an
oil will flow or can be poured. The pour point is
measured under specific test conditions. Fuel oil
must be stored, handled and pumped at ternpera-
tures above the pour point to avoid wax crystalliza-
tion, which may result in precipitation in storage
tanks, blocking of filters and pipe lines and preven-
tion of pumpability. Normally, the pour point of re-
sidual fuel oil does not create any problems, since
the temperature needed to reduce the viscosity to
pumpable levels will be adequately in excess of the
pour point.

Carbon Residue %weight Flash Point

Asphaltenes %weight
Diesel Index
The flash point of an oil is defined as the temperature
Engine- FIA
Relevant Ash
at which it gives off sufficient vapour to create an
% weight
Properties Sulphur % weight inflammable mixture with air. This mixture will ignite
Water % volume or flash under the influence of an open flame, but will
Vanadium PPm not support combustion itself. The flash point of fuel
Sodium PPrn oil is normally tested by the Pensky-Martens closed-
Silicium Oxide pprn
Aluminium Oxide
up method.
pprn

Viscosity cSW5O"C In order to provide a sufficient margin of safety from

Installation- Density glml fire risk during storage, handling and transportation,
Relevant Flash Point "C fuel oils for shipboard use must meet the classifica-
Properties Pour Point "C
tion societies' requirements of flash point, limited to
a minimum of 60°C (140°F).
Table 2 Analysis data for fuels

02.16- ESO - G
 Description
Page 1 (2) Fuel Oil Cleaning 504.30
Edition OIH

General
Purification Recommendations Especially for fuels above 180 cST/5O0C(1500 sec.
RW/lOO°F)the highest possibletemperatureof 98°C
Fuel oils are always contaminated and should (208°F) should be maintained in the centrifuge oil
therefore be cleaned thoroughly of solid as well as weheater.
liquid contaminants before use. The solid contami-
nants in the fuel are mainly rust, sand, dust and re- The fuel is kept in the centrifuge for as long as
finery catalysts. Liquid contaminants are mainlywater, possible by adjusting the flow rate through the
i.e. either fresh water or sea water. centrifugeso that it corresponds to the amount offuel
required by the engine without excessive re-
The impurities can cause damage to fuel injection circulating. Consequently, - the centrifuge should
pumps and fuel valves, result in increased cylinder operate for 24 hours a day except during necessary
liner wear and cause the exhaust valve seats to cleaning.
deteriorate. Increased fouling of gasways and
turbocharger blends may also result from the use of Taking today's fuel qualities into consideration the
inadequately cleaned fuel oils. need to clean centrifuges ("shooting frequency")
should not be underestimated. Correct choice and
Effective cleaning can only be ensured by means of adjustment ofthe regulating screwsandlorthegravity
a centrifuge. We recommend that the capacity of the discs are of special importance for efficient water
centrifuges installed be at least according to the removal. The centrifuge manual states the disc or
centrifuge maker's recommendations. To obtain screw adjustment which should be chosen on the
optimum cleaning it is of the utmost importance to basis of the specific gravity of the fuel.
operate the centrifuge with as low a viscosity of the
fuel oil as possible and to allow the fuel oil to remain Normal practice is to have at least two centrifuges
in the centrifuge bowl for as long as possible. available forfuel cleaning. Resultsfrom experimental
work on centrifuges, treating today's qualities of
residual fuel, have shown that the best cleaning
effect, especially as regards removal of catalyst
Cleaning of HFO by Centrifuging
fines, is achieved when the centrifuges are operated
I
in series, in purifiertclarifier mode.
options Two centrifuges in parallel.
Two centrifuges in series.
Therefore series operation of centrifuges to ensure
maximum safety is a fully accepted alternative to the
Optimum Operating Configurations previously recommended parallel operation, provided
I the operating capacity of each individual centrifuge
Water content Parallel operation can handle the total amount of fuel required by the
below 1 % Purifier / Purifier engine, without exceeding the flow rate recommended
Nomlal
or by the centrifuge maker for the operating mode in
conditions
Density at 15'C Series operation question.
below 0.991 Purifier + Clarifier
If the centrifuge capacity installed is on the low side,
N
7

m' Water content corresponding to the specific viscosity of the fuel oil
9 used, and if more than one centrifuge is available,
W below 1 % Parallel operation
2
0
In
parallel operation may be considered in order to
In
N
Extreme Density at 15°C Purifier / Purifier obtain an even lower flow rate. However, in view of
F
D
0
conditions below 0.991 the above results and recommendations serious
m
N consideration should be given to installing new
m
0
o High content Series operation equipment in accordance with today's fuel qualities
of catalyst fines Purifier + Clarifier and flow recommendations.

Table I. Cleaning of HFO.

97.40 - ESO ---- ----

-- - ---
--
F?===?

CWERATNC SETS
504.30 Description
Edilion 01H Fuel Oil Cleaning Page 2 (2)

General

To determine centrifuging capacity we generally

advise to follow the recommendations of the Flow Rate
centrifuge maker, but the curves in fig. 1, can be Related to Rated Capacity of Centrifuge
used as a guideline.

Ahornogenizer may be installed in the fuel oil system

as a supplement to the centrifuges in order to
homogenize possible water and sludge still present
in the fuel after centrifuging.

l O F =-C
Separation
/
Temperature

I Log scales 30 6080

, , ,
/
1 i 0 18d600 = c s T ~ ~ ~ ' c
t
200 400 600 1500 3500 6000 sec. RII1OO"F

Fig. I Flow rate through centrifuge related to nominal capa-

c 0 of centrifuge.

97.40 - ESO
 Description
Page 1 (5) Freshwater System Treatment
P r o t e c t i o n a g a i n s t C o r r o s i o n in F r e s h w a t e r
Cooling System
The engine fresh water musf be carefully treated,
maintained and monitored so as to avoid corrosion
or the formation of deposits which can result in
insufficient heat transfer, it is necessary to treat the
cooling water. MAN BBW recommend that this treat-
ment is carried out according to the following proce-
dure:
- Clean the cooling water system.
- Fill up with deionized or distilled cooling water
(for example from the freshwater generator)
with corrosion inhibitor added.
- Carry out regular checks of the cooling water
system and the condition of the cooling water.
Observance of these precautions, and correct ven-
ting of the system, will reduce service difficulties
caused by the cooling water to a minimum.
C l e a n i n g of t h e C o o l i n g W a t e r S y s t e m
Before starting the inhibition process, any existing
deposits of lime or rust, or any oil sludge, should be
removed in order to improve the heat transfer and to
ensure uniform protection of the surface by means of
the inhibitor.
The cleaningshould comprise degreasing to remove
oil sludge, and descaling with acid afterwards to
remove rust and lime deposits.
Ready-mixed cleaning agents, specially made for
cleaning the cooling water system, can be obtained
from companies specializing in cooling water treat-
ment. Thesecompaniesoffer assistance and control
ofthe treatment in all majorports. A number ofthese
companies are mentioned on the enclosed list. We
point out that the directions given by them should be
closelyfollowed.-It is of particular importance to flush
the system completely after cleaning.
1 504.40
Edition 02
1
General
Cleaning agents emulsified in water as well as
slightly alkaline cleaning agents can be used for the
degreasing process, whereas ready-mixed cleaning
agents which involve the risk of fire must obviously
not be used. For descaling with acid, especially
products based on amino-sulphonic acid, citric acid,
and tartaric acid are recommendable, as these acids
are usually obtainable as solid substances, easily
soluble in water, and do not emit poisonousvapours.
The cleaning agents should not be directly admixed,
but should be dissolved in water and then added to
the cooling water system.
Normally, clean~ngcan be executed without any
dismant\ing of the engine. We point out thatthe water
should be circulated in the engine toachieve the best
possible result.
As cleaning can cause leaks to become apparent in
poorly assembled joints or partly defective gaskets,
inspection should be carried out during the cleaning
process. The acid content of the system oil should
also be checked immediately after cleaning, and 24
hours afterwards.
C o o l i n g Water - Inhibitors
Thefilling-up with cooling water and the admixture of
the inhibitor is to be carried out directly after the
cleaning in order to prevent formation of rust on the
cleaned surfaces.
Raw Water
The formation of lime stone on cylinder liners and in
cylinder heads may reduce the heat transfer, which
will result in unacceptably high temperatures in the
material.
Therefore, it is recommended that deionized or
distilled water (for example from the freshwater
generator) is used as cooling water. However, on
account of its lack of hardness, this water will be
relatively corrosive, and a corrosion inhibitor should
therefore always be added.
504.40 Freshwater System Treatment
Edition 02
General
If deionized or distilled water cannot be obtained,
normal drinking water can be used in exceptional
cases. If so, the total hardness of the water must not
exceed 9" dH (German hardness degrees). The
chloride, chlorine, sulphate, and silicate contents are
also to be checked. These contents should not
exceed the following values:
Chloride 50 PPm (50 mglitre)
Chlorine 1@ P P ~ (1 0 mgllitre)
Sulphate 100 ppm (100 mglitre)
Silicate 150 ppm (150 mgllitre)
There should be no sulphide and ammonia content.
Rain water must not be used, as it may be heavily
contaminated.
It should be noted that softening of water does not
reduce its sulphate and chloride contents.
Corrosion Inhibitors
T o protect freshwater cooling systems in marine
diesel engines against corrosion, various types of
inhibitors are available.
Generally, only nitrite-borate based inhibitors
are recommended.
A numberofthe products marketed by majorcompa-
nies are specified on the enclosed list, togetherwith
the necessary dosages and admixing procedures.
W e recommend that these directions are strictly
observed.
Treatment of the cooling water with inhibting oils is
not recommended, as such treatment involves the
risk of oil adhering to the heat transmitting surfaces.
Chromate inhibitors must n o t b e used in plants
connected t o a freshwater generator.
Evaporated cooling water is to b e replaced with
noninhibited water, whereas a loss of water through
leakage must be replaced with inhibited water.
When overhauling individual cylinders, a new dos-
age of inhibitor must, if necessary, be added im-
mediately after completing the job.
Description
Page 2 (5)
C h e c k i n g o f t h e C o o l i n g Water S y s t e m and
the C o o l i n g W a t e r d u r i n g Service
If the cooling water is contaminated during service,
sludge or deposits may form. The condition of the
cooling water system should therefore be regularly
checked, especially if deionized or distilled water is
not used. If deposits are found in the cooling spaces,
these spaces or: if necessary, the entire system
should be cleaned.
According to experience, a zinc galvanized coating
in the freshwaie: cooling system is often very sus-
ceptible to corrosion, which results in heavy for-
mation of sludge, even if the cooling water is cor-
rectly inhibited. The initial descaling with acid will, to
a great extent, remove the galvanized coating. Gen-
erally, therefore, we advise against the use of galva-
nized piping in the freshwater cooling system.
The quality of the cooling water is to be checked
regularly, if possible once a week. Basically the
inhibitorconcentration, the pH value and the chloride
concentration should be in accordance with limits
stated by inhibitor manufacturer. For this purpose
the inhibitor manifactures normally supply simple
test kits.
As a general guidancevaluesthepH valueshould be
7-10 measured at 20" C and the chloride concentra-
tion should not exceed 50 ppm (50 mgllitre).
The water sample forthese tests is to be taken from
the circulating system, and not from the expansion
tank orthe pipe leading to it.
The concentration of inhibitor must under n o
circumstances be allowed to fall below that re-
commended b y the producer, as this w o u l d in-
crease the risk o f corrosion.
N
7
m
A clear record of all measuring results should be 2
kept, so that the actual condition and trend of the v)
system may be currentlyascertained and evaluated. 2
F
0
Asudden or gradual increase in the chloride content g
of the cooling water may be indicative of salt water g
leakages. Such leakages are to be traced and repai-
red at the first opportunity.
 ZJMD - B&W
Description
Freshwater System Treatment
Page 3 (5)
A chloride content in the cooling water higher than
the 50 ppm specified might, in exceptional cases be
tolerated. However, in that case the upper limit
specified by the individual inhibitor supplier must not
be exceed.
A clear record of all measuring results should be
kept, so that the actual condition and trend of the
system may be currentlyascertained and evaluated.
A sudden or gradual degrease in pH value, or an
increase of the sulphate content, may indicate ex-
haust gas leakage. The pH value can be increased
by adding inhibtor; however, if major quantities are
necessary, the water should be replaced.
Every third month a cooling water sample should be
sent ashore for laboratory analysis, in particular to
ascertain thecontents ofinhibtor, sulphate, and iron,
as well as the total salinity ofthe water.
Cleaning and Inhibiting Procedure
The engine must not be running during the cleaning
procedure, as this may involve the risk of overhea-
ting when draining.
Degreasing
Use clean tap water for filling-up. The cooling water
in the system can be used, if it does not contain
inhibitors.
Heat the water to 60" C and circulate the water
continuously.
Drain to lowest water level in expansion tank.
Add the amount of degreasing chemical specified by
the supplier, preferably from the suction side of the
g freshwater pump.
N
L0
z Normally, the shortest time recommended by the
a
4
Drain to lowest water level in the expansion tank
8
0
directly afterwards.
m
0 longer time must be reckoned with. Check every
Circulate the cleaning chemical for the period speci-
fied by the supplier.
504.40
Edition 02
General
The cooling water system must n o t be kept
under pressure.
Check, and repair any leaks.
Drain the system and fill up completelywith clean tap
water, in orderto flush out any oil or grease from the
tank.
Circulate the water for 2 hours, and drain again.
Descaling with Acid S o l u t i o n
Fill up with clean tap water and heat to 70-75" C.
Dissolve the necessary dosage of acid compound in
a clean iron drum with hot water.
Fill the drum half up with water and slowly add the
acid compound, while stirring vigorously. Then fill
the drum up completely with hot water while conti-
nuing to stir (e.g. using a steam hose).
Be careful- use protectivespectacles andgloves.
For engines which have been treated before the trial
trip, the lowest concentration recommended by the
supplier will normally be sufficient.
For untreated engines, a higher concentration -
depending on the condition of the cooling system -
will normally be necessary.
Drain some water from the system and add the acid
solution via the ex~ansiontank.
The cooling water system must not be put under
pressure.
Keep the temperature of the water between 70" C
and 75" C, and circulate it constantly. The duration
of the treatment will depend on the degree offouling.
supplier will be sufficient for engines which are
treated before the trial trip. For untreated engines, a
hour, for example with pH-paper, that the acid in the
solution has not been used up.
 MAN 't
h4 s aw i
504.40 Freshwater System Treatment
Edltlon 02
General
A number of descaling preparations contain colour
indicators which show the state of the acid solution.
If the acid content is exhausted, a new acid solution
can be added, in which case, the weakest recom-
mended concentrat~onshould be used.
The solubility of acids in water is often limited.
Therefore if, in exceptional cases, a large amount is
required, descaling can be carried out in two stages
with a new solution of compound and clean water.
Normally the supplier will specify the maximum
solubility.
After completing the descaling, drain the system and
flush with water. Acid residues can be neutralized
with clean tap water containing 10 kg soda perton of
water. Circulate the mixture for 30 minutes, then
drain and flush the system.
The cooling water system m u s t not be put under
pressure.
Continue to flush until water used is neutral (pH
approx. 7).
Descr~pt~on
Adding of Inhibitors
Fill up the cool~ngwater system with water from the
evaporatortothe lowest water level in the expansion
tank.
Weight out the quant!ty of inhibitors specified by the
supplier and dlssolve in a clean iron drum with hot
water from the eva~orator.
Add the solution via the expansion tank to the
system. Then fill up to normal water level with water
from the evaporator.
Allow the engine to run for not less than 24 hours to
ensure that a stable protection of the cooling surfa-
ces is formed.
Subsequently, test the cooling water with a test kit
(available from the inhibitor supplier) to ensure that
an adequate inhibitor concentration has been obtai-
ned.
This should be checked every week.
The acid content of the system oil is to be checked
directly after the descaling with acid, and again 24
hours afterwards.
 ZJMD - E&W

Description
Freshwater System Treatment 504.40
Page 5 (5) Edition 02

General

Nitrite-borate corrosion inhibitors

for cooling water treatment

Maker's minimum
Company Name of Inhibitor Delivery Form Recommended
Dosage*

Castrol Limited Castrol Powder 3 kg11000 I

Swindon Solvex WT4
Wiltshire, England Castrol Liqutd 20 111000 1
Solvex WT2

Drew Ameriod
Marine
Boonton, N.J.1U.S.A l
DEW[-NC
Liquidewt
Maxiguard
Powder
Liquid
Liquid
1 3.2 kg11000 I
8lll0OOl
16 111000 1
I
Houseman Scandinavia Cooltreat 651 Liquid 5 111000 1
3660 Stenlerse
Denmark Cooltreat 652 Liquid 5 111000 1

Nalfleet Marine Chemicals Nalfleet EWT Liq

Northwich, (9-108) Liquid 3 111000 1
Cheshire CW8DX, England Nalfleet EWT 9-1 31C Liquid 10 111000 1
Nalfleet EWT 9-1 1 1 Liquid 10 111000 1
Nalcool2000 Liquid 70 1/1000 l

Rohm & Haas R D l l DIA PROSIM Powder 3 kg11000 I

(ex Duolite) RD25 DIA PROSIM Liquid 50 111000 1
Paris, France

Unitor Rochem Dieselguard NB Powder

Marine Chemicals Rocor NB Liquid Liquid
Oslo, Norway

*
Initial dosage may be larger

1
N
F The list is for guidance only and must not be The suppliers are listed in alpabetical order.
m'
9 considered complete. W e undertake no responsi-
g b~lityfor difficulties that might be caused by these or Suitable cleaners can normally b e supplied by
m
l N
m other water inhibitoslchemicals. these firms.
I
5
I
2
N
0
m
0
 1 "d;;;~ ' Cylinder Head

I
jcylinder head and water jacket I

I
!D~smantlrngof cylinder unit from engrne ' ~ G ~ - ~ L . (Q0Q1 ~ ) jI
t
~D~sassernbly
of cvl~nderunit l555-Ql.Cli ( E 2 H ) 1i
I
jlnspect~onof inlet valve, exhaust valve and valve
I 535-02.05 407H) 1
lgulde iI
I

iRecondit~oningof valve spindle seat and valve sea:

, .rgs-on.r8 ( o 2 E j
Iring
,VaI v ~rotator 505-Cli.35 {OZi-E)
;Replacement of valve gurde sgs-al.zC ( 0 5 H ) I

I
:Replacement of valve sear: ring 505-01.35 {85S] I
I
1

/ ~ n s p e c t ~ oofn cylinder head cool~ngwater space ;505-01.45(025) i

I Ii
iAssembly i505-02.50 (02H)
i _ _ . - - .of- -cylinder
_._ - _
un~t
_ - . - --
i
I

I K I for
~ cylinder
- -
unit
-"
i5050Q-lQZ
1

i
,
j ~ rfor
t complete cylinder unit exchange
- - - - -
i50580-Ifk
-
1
. - I - I
I i
/Cylinder head
- - - -- - . - -- - - . . --
,5Cj501-IPH
- - - -.- I
;valve spindles and valve gear
- -
i50502-08H
-
1i
Cylrnder head, top cover ' 5 0 5 3Q-Q2H i
Cylinder unit /50515-04H
i
- . . *
 ZJMD - E&W
Description
Page 1 (1) Cylinder Head and Water Jacket
Cylinder Head
The cylinder head is of cast iron with an integrated
charge air receiver, made in one piece. It has a bore-
cooled thick walled bottom. It has a central bore for
the fuel injection valve and 4valve cross flow design,
with high flow coefficient. Intensive water cooling of
the nozzle tip area made it possible to omit direct
nozzle cooling. The valve pattern is turned about 20"
to the axis and achieves a'certain intake swirl.
The cylinder head is tightened by means of 4 nuts
and 4 studs which are screwed into the engine
frame. The nuts are tightened by means of hydraulic
jacks.
The cylinder head has a screwed-on top cover. It has
two basicfunctions: oil sealing ofthe rocker chamber
and covering ofthe complete head top faceto protect
bolts and reduce noise radiation.
The valve guides are identical and therefor inter-
changeable.
Water Jacket
The main function of this part is as liner waterjacket,
distribution gallery and tappet housing.
Fig l Cylinder head
98.38 - ESO
505.01
Edition 02H
The waterjacket is bolted to the cylinder head by five
bolts. The five connection bolts to the cylinder head
are free accessible from the top side and permit also
a dismantling of the cylinder head itself.
Air Inlet and Exhaust Valves
The valve spindles are made of heat-resistant ma-
terial and the spindle seats are armoured with
welded-on hard metal.
All valve spindles are fitted with valve rotators which
tum the spindles each time the valves are activated.
The turning of the spindles ensures even tem-
perature levels on the valve discs and prevents
deposits on the seating surfaces.
The cylinder head is equipped with replaceable
valve seat rings. The exhaust valve seat rings are
water cooled in order to assure low valve tempera-
tures.
The seat rings are made of heat-resistant steel. The
seating surfaces are hardened in order to minimize
wear and prevent dent marks.
 ZJMD- B&W
r

Working Card 505-01.OO

Page 1 (3) Dismantling of Cylinder Unit from Engine Edition 01H

Safety precautions Special tools

Stopped englne Plate No ltem No Note

Shut-off starting arr
Shut-off cooling water
Shut-off fuel or1
E Stopped lub 011circul
Press Blockrng - Reset

Description

Dismantling of cylinder unit from engine for

inspection andior overhaul.

Starting position Hand tools

Engine stopped and cooled down Unbraco top

Ratchet
Extension

Related procedure

Valve rotator 505-01.15

Disassembly of cyl.head - water
jacket, cyl. liner and piston 505-01.01
Fuel injection valve 514-01.10

Manpower Replacement and wearing parts

Working time : 1 hours Plate No Item No Qv/

Capacity 2 men

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

99.03 - ESO 0406 -- ---

---
E
---
EER~R-ATXC'~~~~
 505-01.OO Dismantling of Cylinder Unit from Engine Work~ngCard
Edrt~on01 H Page 2 (3)

P r e p a r a t i o n before D i s m a n t l i n g 9) Remove the 2 clamps securing the charge air

connections by unscrewingthe locking bolts for
1) Drain off the water from the engine. the clamps.

2) Remove the top cover. 10) Push the charge air connections, inside the
cylinder head wh~chare to be removed.
3) Remove the side covers on both sides of the
engine. 11) Turn the piston to top position.

4) Remove the exhaust gas cover.

Removal of B e a r i n g Cap

Disassembly o f Connections 12) Loosen the connecting rod nuts by means of

the hydraulic jacks, see working card 506-
5) Remove the clamp forconnecting cylinderhead 01.25.
and exhaust gas receiver.
13) Remove the connecting rod nuts and bearing
6) Remove the fuel oil high pressure pipe. cap by hand.

7) Remove the 4 clamps securing the fresh water

(FW) connection between thecylinder heads by
unscrewing the locking bolts for the clamps.
X /Lifting tool
8) Push the FW connections inside the cylinder
heads, which are to be removed.

t Charge air connection

Cooling water connection

Fig 1 Push the cooling water connection and charge air

connections inside the cylinder heads, which are be removed
Fig 2 Mounting of liffing and fixing tool.

-
--
E - A c

m
- -----
------- --- --
--
F=--
0406 99.03 - ESO
m T N G SETS
 -.mm*v
/SW -.,.h.

t.:,
ZJMD- 6&W

Working Card
Dismantling of Cylinder Unit from Engine 505-01.OO
Page 3 (3) Edition OIH

M o u n t i n g o f S u p p o r t Tools

14) Mount the fixing part, seeplate 52006item212

for locking the connecting rod to the cylinder
liner.

15) Remove the cylinder head nuts by means of

the hydraulic jacks, see working card 520-
0 1.05.

c
Fig. 4 Cyiinder unit placed in work table.

16) Mount the lifting tool on the cylinder head, see

plate 52005 item 038.

Removal o f Cylinder Unit f r o m Engine

17) Lift the cylinder unit just enough for removing

the upper connecting rod bearing shell by
hand

18) Lift carefully the cylinder unit out of the engine

after the upper connecting rod bearing shell is
removed.
Cylinder head
Nut 19) Land and fasten the cylinder unit upon the
special worktable, oron thefloorupon wooden
Cylinder head supports and remove the lifting tool.
bolt

I
Fig 3 Hydraulic tools for dismounting of cylinder head nuts

99.03 - ESO
 Working Card 505-01. O l
Page 1 (3) Disassembly of Cylinder Unit Edition 02H

Safety precautions Special tools

Stopped englne Plate no Item no Note
B Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
B Stopped lub. oil circul.
Press Blocking - Reset

) Description H a n d tools

Dismounting of cylinder head: water jacket, Measuring tools.

cylinder liner and piston for inspectionioverhaul. Allen key, 8 mm.
Ratchet.
Extension.
Serrated fork.

I Starting position
Dismantling of cylinder unit 505-01 .OO

Related procedure
Inlet and exhaust valve - overhaul and
regrinding of spindel and valve seat, 505-01. l 0
Valve rotator, 505-01.15
Replacement of valve guide, 505-01.20
Replacement of valve seat ring, 505-01.35
Inspection of piston, 506-01.l0
Cylinder liner 506-01.35
Separation of piston and
connecting rod 506-01.05
Fuel injection valve 514-01.10

1 Manpower Replacement and wearing parts

2 Working time : 1 hours
m: Plate no Item no Qty!
9
m
U
Capacity 1 man
a
U)
N
U)

r Data
B
W
N
m Data for pressure and tolerance (Page 500.35)
W
m Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

99.03- ESO
 505-01.OI Working Card
Edition 02H
Disassembly of Cylinder Unit Page 2 (3)

Before starting to dismantle the cylinder unit it must Removal of Cylinder Head
be placed on the grinding table.
4) Remove the five allen screws in the cylinder
head
Removal of Piston and Connecting Rod
5) Remove the cylinder head by means of the
l) Remove the fixing part (please seeplate 52006, lifting tool .
item212)from thecylinderlinerand connecting
rod.

2) Turn the unit 180" in the table

3) Pull out the piston and connecting rod with the

aid of the tool as shown in fig. 1.

- Lifting tool

Fig 2 Removal of cylinder head

Connecting rod

Cylinder liner

l I

Fig 1 Removal of piston and connecting rod

-- --
E&= -
-==-
S
- 99.03 - ESO
~-TZCTE?S 0406
 Working Card 505-01 .01
Page 3 (3) Disassembly of Cylinder Unit Edition 0 2 ~

Removal of Water Jacket and Cylinder Liner

Tool
6) Loosen two positioningpins in the waterjacket fi
and remove the two roller guides. . - - ,.! ';".;:c-,.>:.
.
..
.,

7) Lift the cylinder liner out of the water jacket by

means of the lifting tool as shown in fig. 3.

8) Remove the flame ring from the cylinder liner

by means of the tool as shown in fig. 4. Use an
usedlscrapped piston ring.
ring

Lifting tool for

piston ring

Fig 4 Remolal of flame ring

I l

Fig 3 Removal of waterjacket and cylinder liner

99.03 - ESO
 ZJMD - B&W

Working Card 505-01.05

p, (3) Inspection of Inlet Valve, Exhaust Valve and Valve Guide Edition 07H

Safety precautions Special tools

B Stopped engine Plate no Item no Note.

m Shut-off starting air
• Shut-off cooling water 52005 014
Shut-off fuel oil
E Stopped lub. oil circul.
E Press Blocking - Reset

Description Hand tools

Dismounting of inlet and exhaust valve, inspec-

tion of valve guide and mounting of inlet and
exhaust valve.

Starting position

Disassembly of cylinder unit 505-01.01

Related procedure

Reconditioning of valve spindle seat

and valve seat ring 505-01.l0
Valve rotator 505-01.l 5
Replacement of valve guide 505-01.20
Replacement of valve seat ring 505-01.35

Manpower Replacement and wearing parts

Working time : 1 hours Plate no Item no Qv/

Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

03.42 - ESO 0406

-
--
-- --
-
-=--
- ----=--
e
~ ~ T ~ - T ~ c ~ ~
 ZJMD - B&W

1 505-01 1
Edition 07H '05 Inspection of Inlet Valve, Exhaust Valve and Valve Guide / Working Card
page 2 (31

Dismantling of lnlet and Exhaust Valve

Spindles
A Nut

1) Land and fasten the cylinder head upon a

special work table and remove the lifting tool.

Or as an Alternative:

Land the cylinder head on the floor upon

wooden supports and remove the lifting tool.

2) Turn back the rocker arm and remove the

valve bridge over the valve spindles.

3) Install the tool for mounting of valves (6), see

fig 1.

4) Compress valve springs by tightening nut A,

see fig 2.
Fig 2 Mounting of ccnpression tool

/
B Tool for mounting
of valves

Fig 1 Mounting of compression tool.

5) Press valve up to access cone ring, see fig 3 *)

6) Remove cone rings, see fig 3.

7) Release springs again. Fig 3 Removal of cone rings

8) Loosen nut A and extractor plate B, see fig 1.

9) Remove a valve rotator and springs.

10) Repeat point 4 - 9 to remove other valve

spindles.

e
=-
L
-
:-
-
CE-TPJC
ss=--
=
SETS
0406 03.42 - ESO
 Working Card 505-01.05
page3 (3) Inspection of lnlet Valve, Exhaust Valve and Valve Guide EdilianmH

lnspection of ValvesNalve Seats

If the valve seat is burnt or scarred, it should be

I
ground using avalve seat grinder,p/ease see working
card 505-01.10.

lnspection of Valve Guide

Too much clearance between the valve spindle and

the spindle guide may cause:

- increased lub, oil consumption.

- fouling up of the spindle guide and thus give
the risk of the sticking of the valve spindle.

11) Clean the valve spindle guide.

..
12) Inspect and measure for wear.
i l
Ifthe inner diameter of the valve guide ,rig 4 ~ ~valve spimeg2fde
~ for wear. ~ ~ ~
exceeds the tolerance, please seepage 500.35,
the valve spindle guide must be replaced.
Please see working card 505-01.20.

Too much clearance also means insufficient

guidance of the valve spindle, and thus bad
alignment between the spindle head and the
valve seat ring.

Mounting of Valve Spindle

13) For mounting the valve spindle follow the

instructions in point 3-9 in reverse order.

Note:
Please be a ware of the ayfferent valve disk diameter
at inlet a n d exhausf valves.
Inlet valve : 057mrn
Exhaust valve : 054 m m

'
-m
----- FE=3
-
03.42 - ESO 0406 - p -

GENER4TING SETS
- - -
 Working Card Reconditioning of Valve Spindle Seat 505-01.l
0
Page 1 (3)
and Valve Seat Ring Edition 0 2 ~

1 Safety precautions Special tools

l
El Stopped engine
Shut-off starting air
Shut-off cooling water
Plate no

52005
Item no

408
Note

Grinding machine
l
Shut-off fuel oil for valve spindle.
E Stopped lub. oil circul. (extra tools).
Press Blocking - Reset 52005 350 Grinding machine
for valve seat ring
(extra tools).
Description

Reconditioning of valve spindle seat and valve

seat ring, with special grinding machine.

Starting position Hand tools

Valve spindle has been removed 505-01.05 All the hand tools and new stones are included in
the tools box for grinding machine.

Related procedure

Mounting of valve spindle 505-0 1.05

Manpower Replacement and wearing parts

Working time : 3 hours Plate no Item no Qt~l

Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.40 - ESO 0406 -----

---
=A=
-- - -- --
-- -
=-a
a=

CENERATNG SETS
 ZJ M D - E&W

505-01 . l 0 Reconditioning of Valve Spindle Seat Working Card

Page 2 (3)
Edition 0 2 ~ and Valve Seat Ring

Reconditioning of Valve Seat Ring
Reconditioning of valve seat rings by machining is
carried out by means of a grinding machine, the pilot
spindle of which must be mounted in the valve
spindle guide. For operation ofthe grinding machine,
see separate instructions.
However, when seat "S" is ground to such an extent
that recess "R" disappears, see fig I, the valve seat
ring must be scrapped and a new one must be
installed, please see working card 505-01.35
This is only valid for the exhaust valve seat, the inlet
valve seat has no recess due to less wear of the inlet
valve sea:.

Grinding of Valve Seats

Reconditioning of Valve Spindle
Grinding of valve seat rings should be carried out in
the following order: Reconditioning by machining is carried out with the
valve spindle being rotated in a turning lathe and a
1) Grind the seating surface with a feed at an special grinding machine mounted on the tool post of
angle "A" of 30" f the turning latch.
0

2) Continue grinding until a clean and uniform Grinding of Valve Spindle

surface is obtained.
3) Carry out final grinding with a feed in direction
from inside to outwards. Normally, the best
surface quality is obtained this way.
For operation of the grinding machine, see separate
instructions.
l ) Grind the seating surface with a feed at an
angel " A of 30" f oC i"

2) Continue grinding until a clean and uniform

surface is obtained.

r- "S"
3) Check height "H"1 upon completion the
grinding, see fig 2.

"H"1 must be no less than indicated on page

500.35.
If less, the spindle must be scrapped.

Fig 1 Valve Seat Ring

Scraping of Valve Seat Rings

.- Normally, the valve seat ring can be reconditioned

several times.
Fig 2 Valve Spindle

=S=<
y
+ e c-= 98.40 - ESO
QNERATNC SETS
 Working Card Reconditior~ingof Valve Spindle Seat 505-01.l
0
Page 3 (3)
and Valve Seat Ring Edition 0 2 ~

4) After assembling the valves, check bymothing

the valve that distance "H"2 between the upper
edge of the cylinder head and the upper edge
of the valve spindle, see fig 3, does not exceed
the maximum value, please see page 500.35.

Fig 3 Measuremen! of distance HZ.

==-=-=-m---
--
E -S=-=
98.40 - ESO 0406 E =
CEMRATFJG SETS
 ZJMD - B&W

Working Card 505-01.15

P a g e 1 (2) Valve Rotator Edition 02H

Safety precautions Special tools

a Stopped engine Plate no Item no Note

E Shut-off starting air
B Shut-off cooling water
Shut-off fuel oil
Stopped lub. oil circul
Press Block~ng- Reset

Description Hand tools

Dismantling, inspection and mounting of valve Small screwdriver.

rotator. Ring and open-end spanner, 24 mm.

Starting position

Valve spindle has been removed 505-01.05

Related procedure

Mounting of valve spindles 505-01.05

Manpower Replacement and wearing p a r t s

Working time : 1/2 hour Plate no Item no Qty ./

Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.46 - ESO
/"@j";i~*~<
'"h

505-01.l
5 Valve Rotator
Work~ngCard
Page 2 (2)
Ed~t~on
02H

Maintenance and Inspection of Rotocap Note: Having assembled the valve rotator in dry
condition it should be placed in clean lubricating oil
Dirt, especially in the ball pockets due to residues in for a short period of time.
the oil (abrasives, combustion products), can cause
the individual parts to become stuck, and interrupt
the movement of the balls.

Under normal operating conditions rotocap valve

rotators need no servicing.

Rotator performance is satisfactory when the valve

rotates visibly and evenly.

l
Dismantling of Rotocap l
Please see Working Card 505-01.05, steps 3 to 9. Fig 1 Valve rotator

Overhaul of Rotator Mounting of Rotocap

l ) Clean the valve rotator. Please see working card 505-01.05, steps 3 to 9,
opposite direction.
2 ) Remove the retaining ring and disassemble
the individual parts.

3) Inspect for wear and ball impressions.

4) Replace parts showing wear grooves or de-

pressions formed by the balls.

5) Insert the balls and the tangential springs.

Note: All balls on the inclined races of the ball

pockets must point in the same direction, see fig l.

The inner ring ofthe spring washer should rest on the

retainer body.

98.46 - ESO
 ZJMD - B&W

Working Card 505-01.20

Page 1 (3) Replacement of Valve Guide Edition 05H

Safety precautions Special tools

Stopped englne Plate no Item no Note

Shut-off startrng arr
fl Shdt-off coollng water 52005 099
Shut-off fuel or1
Stopped lub oil c~rcul
Press Block~ng- Reset

Description Hand t o o l s

Disrnantlrngand mounting of valve guide for inlet Hammer 1 Lead hammer

and exhaust valve. Nitrogen (N,), orsrmllar.
H7 reamer, 12 mm

Starting p o s i t i o n

Valve spindle has been removed 505-01.05

Related p r o c e d u r e

Mounting of valve spindles 505-01.05

Manpower Replacement and wearing p a r t s

Working time : 314 hour Plate no. Item no. Qtyl

Capacity 1 man 50501 076 4Icyl
50501 088 41cyl

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

01.14 - ESO --
--
m
-- -- =
-----
= === =S=--
=S

CENEQATNG SETS
m
505-01.20 Replacement of Valve Guide
Working Card
Page 2 ( 3 )
Edition 05H

When to Replace the Valve Guide

If the clearance exceeds the max. limit, please see

page 500.35, the valve guide must be replaced.

Dismounting o f Valve Guide

I)Knock the valve guide out from the bottom of

the cylinder head, by means of a mandrel,
which has a shoulder turning that fits into the
valve guide, see fig l .

2) Clean the bore of the cylinder head carefully.

3) Inspect for marks that can prevent mounting

of new valve guide. I
Fig 7 Dismounting of valve guide

Mounting o f Valve Guide

4) Before mounting - cool down the new valve

guide to approx. -70°C with nitrogen or similar.

5) lnsert the valve guide into the bore.

6 ) Knock slightly with the mandrel and a hammer,

see fig 2.

Note: The shoulder of the valve guide must bear

against the cylinder head, by knocking slightly with
the mandrel and a hammer.

7) The valve guide must be reamed with a 012H7

reamer through the whole guide after guide
temperature is equlized.

Fig 2 Mounting of valve guide

01 . l 4 - ESO
 ZJMD - =&W

Working Card 505-01.20

Page 3 (3) Replacement of Valve Guide Edition 054

8) Insert a new 0-ring in the valve guide, before

mounting of the valve spindle.

Correct mounting can easily be done by the

use oftwovalve spindles as mounting tool, one
spindle to be used as support and the other
spindle to be used for pushing the 0-ring
downwards, see fig 3.

Screw-drivers or other sharp tools should never

be used for this purpose.

9) For mounting of valve spindle, please see

working card 505-0 1.05.

Fig 3 inserting a new 0-ring in the valve guide

01.14- ESO
 Working Card
Replacement of Valve Seat Ring
505-01.35
Page 1 (2) Edition 05H

Safety precautions Special tools

l
, Stopped engine Plate No Item No Note
Shut-off starting air
Shut-off cooling water 52005 110
C] Shut-off fuel oil
Stopped lub. oil circul.
@ Press Blocking - Reset

Hand tools

Replacement of valve seat ring for inlet and Hammer.

exhaust valve. Loctite, 648.
Lub. oil.

Starting position

Inlet and exhaust valves have been

removed 505-01.05

Related procedure

Mounting of valve spindles 505-01.10

I

Man power Replacement and wearing parts

Working time : 1 112 hours Plate No Item No Qty. 1

Capacity 1 man

1 Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

01.32 - ESD
505-01.35 Replacement of Valve Seat Ring
Edition 05H
Dismounting of Valve Seat Rings
When reconditioning of a valve seat ring no longer is
possible due to dimensions exceeding thescrapping
criteria, the seat ring has to be replaced.
Dismounting of a valve seat ring is carried out by
means of a special extractor tool set comprising the
components, see fig 1.
Fig 7 Extraction of valve seat n'ng.
Dismounting of a Valve Seat Ring is Carried
out According to the Following Procedure
1) Weld approx. 5 seconds at 3 places around the
old valve seat with electrode.
2) Wait 60 seconds while the seat is cooling down
and the shrink fit compression is relieved.
3) Mount the extraction tool and pull out the used
valve seat. (If the waiting time is not observed
the tool might be damaged).
4) The valve seat is easy removed by turning the
handle.
Working Card
Page 2 ( 2 )
Mounting of Valve Seat Rings
5) Prior to mounting of a new valve seat ring, the
bore must be cleanedthoroughlyand inspected
for marks. Marks that can hinder mounting of
the valve seat ring must be removed.
6) To facilitate the valve mounting of the seat ring
it must be cooled down, however, a max. of
-25' C otherwise, the 0-ring can be damaged.
7) Place the 0-ring on the valve seat ring and
coat with oililoctite as shown in fig 2,just before
positioning it in the bore.
Coat with
loctite 648
ring
Coat with oil
L I
Fig 2 Coat with oillloctite.
8) Prior to mounting ofthe valve spindle the valve
seat ring must be ground, to ensure correct
centenng afthe valve guide and the valve seat
ring. This can be done according to working
card 505-01.10.
01.32 - ESO
 Working Card
Page 1 (2) Inspection of Cylinder Head Cooling Water Space 505-01.45
Edition 02H

1 Safety precautions Special tools

Stopped engine Plate No Item No Note

Shut-off start~ngair
Shut-off cool~ngwater
Shut-off fuel 011
Stopped lub oil circul
E? Press Blockrng - Reset

Description Hand t o o l s

lnspection of cylinder head cooling water space. S;eel brush

S t a r t i n g position

The cylinder head dismantled

from engine 505-01.OO

Related procedure

m'
1 Manpower Replacement a n d wearing parts
9
d
m
Working time : X hour Plate No Item No Qtyl
5
m Capacity 1 man
-m
m

U
4
m
(\I
0
m
-.
0
1 Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.38 - ESO 0406 - --- - ---

--
7 L&=
- - m
m----
CEMRATWC SETS
 ZJMD -
505-01'45 Inspection of Cylinder Head Cooling Water Space
Working Card
Page 2 (2)
Edition 02H

lnspection of Cylinder Head Cooling Water

Space

l) Inspect the cooling water inlet at the bottom of

the cylinder head, see fig l.
Inspect
2) Remove all possible deposits.

3) If necessary, clean the cooling water inlet and

cooling water outlet, see fig l with a steel
brush.

Flush the cooling water space after cleaning.

Inspect

4) Should the cylinder head cooling water space,

contrary to expectation, be blocked with de-
posits, please contact MAN B&W Diesel,
Holeby for further instructions.

Fig I Cooling water spaces to be inspected.

--
F
-
---
p - - - -
a406 98.38 - ESO
=-TNCSE??S
 ZJMD -
Work~nagCard 505-01.50
Page 1 (3) Assembly of Cylinder Unit Edition 02H

Safety p r e c a u t i o n s Special t o o l s

Stopped engine Plate no Item no Note

Shut-off startrng air
m Shut-off cooling water
E Shut-off fuel oil
E Stopped ub. 011circul.
6 Press Blocking - Reset

Description

Mounting of cylinder head, water jacket, cylinder

liner and piston after inspection/overhaul.

Starting p o s i t i o n Hand t o o l s

Cylinder unit, dismantled, 505-01.01

Related p r o c e d u r e

Mounting of cylinder unit in engine, 505-01.55

Inspection of valve roller guides, 508-01.00
'

Manpower Replacement a n d w e a r i n g p a r t s

Working time : 1 112 hours

.-
N
cd Capacity 1 man
Plate no
5050 1
item no
111
Qtyl
21cy l
0
i 50501 135 lIcy1
0
LD
N
V)
50501 196 lIcyl
I Data 5061 0 031 Ilcyl
g
W
50610 043 l/cyl
N
a Data for pressure and tolerance (Page 500.35) 5061 0 055 lIcy1
W
D Data for torque moment (Page 500.40) 50610 092 Ilcyl
Declaration of weight (Page 500.45)

98.47 - ESO 0406 --

E =-E?
- - m
---
=
---
-=
-
=E?iEz-r=Gs
 505-01.50 Working Card
Edition 02H
Assembly of Cylinder Unit Page 2 (3)

Preparing before Mounting

1) Place the water jacket on the table

2) Place two new o-rings on the cylinder liner and

slightly lubricate with oil.

3) Mount the cylinder liner with a new flame ring

in the water jacket by means of the lifting tool
for the liner, see fig I .

Fig 2 Marking on the cylinder liner and the water jacket

7) Mount the cylinder head by means of lifting

tool (plate 52005, item no 38)

.- 8) Mount the five allen screws in the cylinder

head and tighten up all thescrews, pleasesee
page 500.40.
Fig 1 Mounting of new flame ring

Mounting the Piston

Note: Be sure the marking on the cylinder liner
corresponds to the marking on the water jacket of Before mounting the piston turn around the cylinder
the assembly,see fig 2. unit.

4) Fit a new sealing ring on the cylinder liner. Note: After an overhaul the cylinder liner must
always be honed and the piston must be fitted with ,
.
7

5 ) Mounttwo rollerguides in the waterjacket, see new piston rings, see Working Card 506-01.35. m
9
Workirig Card 508-01.00.
9) Mount the piston guide bush around the cylin-
-8
a
d

m
der unit.
Mounting of C y l i n d e r Head 5
Lift the piston and connecting rod by means of
2
10) g
m
6) Place two new o-rings at the top of the water a suspension. 0

jacket and slightly lubricate with oil.

--
€
S-
"
-
-TIN0
'=
=-
S
L
-
=
-
-
-

SETS
= 98.47 - ESO
 ZJMD - S&W

Working Card 505-01 -50

Page 3 (3) Assembly of Cylinder Unit Edition 02H

11) Lubricate the piston rings and the cylinder liner

with oil.

12) Slowly lower the piston into the cylinder liner.

Note: Be sure that the "st" mark at the top of the

piston is placed on to the fuel pump side.

13) Place wooden wedges betweenthe connecting

rod and the piston shirt.

14) Remove suspension tool from the connecting

rod.

15) Mount fixingparttool (plate52006item212)

to the connecting rod and the cylinder liner.

98.47 - ESO 0406 -- - - -=

-- --
=S-
- p -
m --W

GENERATING SETS
-
 i MAN'
t B&W i
Working Card 505-01.55
Page 1 (4) Mounting of Cylinder Unit in Engine Edit~on02H

Safety precautions Special tools

Stopped englne Plate No ltem No Note

B Shut-off start~ngair
Shut-off cool~ngwater
Shut-off fuel oil
E Stopped lub. 011circul.
Press Blocking - Reset

Description

Mounting of cylinder unit after inspection andlor

overhaul.

Starting p o s i t i o n Hand tools

Cylinder unit is competely assembled. Lub. oil and copaslip.

Valve gear of respective cylinder is in
the proper position (valve closed).
Control of the surface of the engine.

Related p r o c e d u r e

Adjustment of valve clearance 508-0 1.10

Manpower Replacement and w e a r i n g parts

Working time : 1 'l2 hours Plate No Item No Qtyl

Capacity 2 men

Data

Data for pressure and tolerance (Page 500.35)

I
Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

-------
-- --
A
-~
F=--=
99.03 - ESO 0406
~ K c i s
 505-01.55 Mounting of Cylinder Unit in Engine Working Card
Edition 02H Page 2 (4)

Preparring before mounting Mounting of the Big-end Bearing

Before the cylinder unit is mounted in the engine, be 3) Make sure the crank throw is in the top posi-
sure to clean the joint faces carefully. tion.

4) Mount the upper part of the big-end bearing

Placing of t h e Cylinder Unit in Engine shell just before the connecting rod is landed
on the crankshaft.
1) Place an 0-ring around the roller guides and
0-rings around the oil connection between the Note: Lubricate the crankshaft with clean lubricating
engine and the water jacket. oil.

2) Lower the cylinder unit slowly into the engine 5) Land the connecting rod on the crankshaft
by means of a lifiing tool, (plate 52005 ifem
038). During this the connecting rod must be guided
by hand to ensure correct approach and lan-
ding in the journal.

6) Remove the fixing part, (plafe 52006 ifem

Lifting tool 212).

7) Mount the bearing cap with the inserted lower

shell of the big-end bearing by hand.

Tightening of t h e Connecting Rod

Note: Iden.No. on the connecting rod and on the

bearing cap must always be the same.

I I
Fig 1 Lifting tool

Fig 2 Clip on/off

=
--
=
"
5
---LY
--
"S--=-=
-
D406 99.03 - ESO
(3EMRATNC SETS
 ZJMD -
Working Card
Mounting of Cylinder Unit in Engine 505-01.55
Page 3 (4) Edition 02H

8) Lubricate threads and the contact face of the 13) Place the spacer ring around the nuts with a
connecting rod screws with molycote paste or slot in such a position that the tommy bar can
the like. be used.

9) Mount bolts and nuts and tighten them firmly
with a tommy bar.
For tighting connecting rod bolts, please see
working card 506-0 1.25.
14) Tighten the hydraulicjacks and make sure that
the cylinder of the jacks bears firmly on the
spacer ring. Tighten up all the nuts, see
descripfion 500.40. For usage of the hydraulic
tools, please see working card 520-01.05.

Note: If new studs or nuts are fit, the nuts must be

Tightening of Cylinder Head Nuts tightened and loosened three times, in order to
compensate for deformation of the thread and in
10) Coat the cylinder stud threads and contact order to ensure a safe minimum load of the studs
faces with copaslip or the like. through the tightening.

11) Fit the cylinder head nuts and make sure that
they run easily and that they bear on their Assembling of Connections
entire contact surfaces.
15) Mount theexhaust clamp between the cylinder
12) Tighten the nuts lightly with a tommy bar head and the exhaust pipe.

Note: Turn clamps correctly as they are not

symmetrical, see fig 4.

Fig 4 Correct mounting of clamps

Cylinder head
Nut 16) Place new 0-rings on water connections and
push the connections into the cylinder head.
Cylinder head
bolt
--
I 17) Secure the water connections with clamps
and tighten bolts on the clamp.
Fig 3 Hydraulic tools for mounting of cylinder head nuts.

99.03 - ESO
505-01.55 Mour~tingof Cylinder Unit in Engine
Working Card
Page 4 (4)
Edition 02H

18) Place new 0-rings on the charge airconnection 22) Bleed airfrorn theventingscrews on the charge
and push the connections into the next cylin- air cooler.
der head.
23) Bleed airfrorn theventing screws on the engine
19) Secure the charge air connection with a clamp top, or bythe flange, connection F3, venting to
and tighten the bolt on the clamp. expansion tank.

20) Mount the high pressure fuel oil pipe, please 24) Open connection G2, L.T. fresh water - outlet.
see working card 514-01.05.
25) Check for leakage.

Ventilation
Adjustment of Valve Clearance
The GenSet is self-ventilating. This means that it is
not necessary for the engine to vent the system 26) Adjust the valve clearance, see working card
before start. 508-01.10.

However, to avoid problems i n the ship's installation, 27) Mount the side and top covers.
w e recommend to ventilate. This can be done in the
following way:

21) Open connection G1, L.T. fresh water - inlet.

99.03 - ESO
 Plate
Page 1 (2) Kit for Cylinder Unit 50500-1 OH

03.50 - ESO
50500-1OH Kit for Cylinder Unit Piate
Page 2 (2)

l I
I
Ordering Number of Kit for Cylinder Unit
1
1
According to list below
1 Plate 50500-1OH IItem 021
1

ltern
NO Qty Designation Where to find in the engine instruction book

Kit for cylinder unit, complete Plate 50500 Item 021

consisting of:

4/C 0-ring Plate 50501 Item 076

2/C 0-ring Plate 50501 ltem 111

?/C 0-ring Plate 50501 Item 135

2/C 0-ring Plate 50501 ltem 172

1/C 0-ring Plate 50501 ltem 196

1/C 0-ring Plate 50501 ltem 231

21C 0-ring Plate 50501 ltem 243
1/C 0-ring Plate 50502 ltem 237
1/C 0-ring Plate 50502 ltem 250
1IC 0-ring Plate 50510 ltem 014
1/C Sealing ring Plate 5061 0 ltem 031
1/C 0-ring Plate 50610 ltem 043
l/C 0-ring Plate 50610 ltem 055

2/C 0-ring Plate 51230 ltem 027

2N 0-ring Plate 51402 ltem 033

1N 0-ring Plate 51402 ltern 104

1/C 0-ring Plate 51404 ltem 022
1/C 0-ring Plate 51404 ltem 046
4/C S e a l ring Plate 51630 ltem 033

Please Note that t h i s is a kit supply, a n d that

a n y exceeding n u m b e r of o-rings a n d g a s k e t s
a r e not accepted a s return goods.

03.50 - ESO
 ZJMD - E&W

Plate
Page 1 (2) Kit for Complete Cylinder Unit Exchange ( 50500-11 H I

03.50- ESO 0406

- ---
- - --
-5m----
----
CL=?
---
GENERP;TlNC S E E
 Plate
Kit for Cylinder Unit Page 2 (2)

l
i
Ordering Number of Kit for Cylinder Unit 1
I

l
According to list below i
Plate 50500-1lH I ltem 045
pp I
Item
No Qty Designation Where to find in the engine instruction book

015 l l Kit for cylinder unit, complete

consisting of:

( 2IC ( 0-ring
Plate 50500

Plate 50501
Item 045

Item 11 1

] IIC 1 0-ring Plate 50501 Item 231

0-ring Plate 50501 ltem 243

0-ring Plate 50510 ltem 014

0-ring Plate 50610 ltem 043

0-ring Plate 51230 ltem 027

0-ring Plate 51402 ltem 033

0-ring Plate 51404 ltem 022

0-ring Plate 51404 Item 046

Seal ring Plate 51630 ltem 033

Please Nofe that this is a kit supply, and that

any exceeding number ofo-rings and gaskets
are not accepted as return goods.

03.50 - ESO
 ZJMD- B&W

Plate
Page I (2) Cylinder Head 50501-1lH

218

See plate 50610

03.50 - ESO 0406

- = - = --- -
=GENERA=
-
-
:&
-A
F=-4
=
SETS
 Plate
50501-1lH Cylinder Head Page 2 (2)

Item
no Qty Designation Benawnelse Designation Benavnelse

015 1
l l
2IC (Guide for valve bridge Slyr for ventilbro
I
027 1 1IC /Cylinder head Cylinderdzksel
I
039 I ZIC (plug Prop
I
052 1 liC l Sleeve Foring
l

088 1 4iC (Valve guide Ventilstyr

l

/ 2iC Valve seat ring,

iniet
Ventils~dering,
indstr~mning

147

159

160
1
) /l

2/C
1
2/C / S t o p screw

Loctite

Cylindrical pin
Stopskrue

Loctite

Cylindrisk stift
I

184

/ 2iC Valve seat ring,

Jerhaurt
Ventils~dering,
udst~dning

206 / Sic /Screw Skrue

l
211 / l i C / w a t e r guide jacket Kslekappe
l
243 2iC 0-ring 0-ring

255 2iC Bolt Bolt

267 liC Stud Tap

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsd side 500.50.

= Only available a s part of a spare parts kit. = Kun tilg~ngeligsom en del af et reservedelss=t.
QtylC = QtyiCylinder QtyIC = QtylCylinder
Qtyil = Qtyllndividual Qtyil = Qtyllndividuelt

--~- =E-E=- i i ~ i G ~ F ~ 7 s
===E
PYF 0406 03.50- ESO
 l Plate
Page 1 (2) Valve Spindles and Valve Gear 1 50502-08H

03.50- ESO
 ZJMD - B&W

Plate
Valve Spindles and Valve Gear Page 2 (2)

Item
no Qty Designation Benzevnelse Designation Benaevnelse

l
11C Rocker arm, exhaust Vippearm, udstods,
complete, incl. item kornplet rnkl tern 034,
034,046,058,071,083 046, 058, 071,083
O1OI
022 11C Rocker arm, inlet Vrppearm ~ndsugn~ng
complete, incl. item kornplet ~ n k~tem034,
034,046,071,083,105 046. 071 063 105

034 1 2lC l Bolt Bolt

I
046 I ZIC IBearing bush Leje
I
058 1 1 ?/C l o c k e r arm. exhaust V r p p ~ a mu d i ~ o ? r
I

l I
083 ZiC Adjusting screw corn- J~s:s-oarskruekomplet
plete, incl. item 095 1 1 6 [:em 005,117,142
117,142

1 l Circlip l
I
095 ZiC Fjetisrmg

105 I I C /Rocker arm. inlet I 1 ~ p p s n nnr'sugnng

,
l
129 ) ZIC l i h r u s t piece Tryksty~~e
I
130 ZiC Valve b r i d g e c o m - Ventilbro komple!, inkl.
plete, incl. item 071, item 071, 129,154 166
129,154,166

142 ( ZIC (Adjusting screw Justerbar skme

lI
1
1 l
154 2/C lAdjusting screw Justerbar skme

156

/
21C

1
Valve bridge Ventilbro
I
178

1
4lC

1
Conical ring a2 Konisk ring 212
I
191

1
4lC Rotocap complete Rotatianspiver.komplet
I
201 "C (Spring Fjeder
I
213 1 l i C Iscrew Skrue
I
249 1 lShan liC
Aksel
l
262 2/C Valvespindle,exhaust Ventilspindel, udst~ds

274 ZC Valve spindle, inlet Ventiispindel, indsugn.

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsi side 500.50

= Only available as part of a spare parts kit. = Kun tilg~ngeligsom en del af et reservedelss~t.
=
.-. QtylC QtylCylinder QtylC = QtylCylinder

03.50 - ESO
 ZJMD - B&W

Plate
Page I(2) Cylinder Head, Top Cover 5051 0-02H

98.41 - ESO 0406 --==E

m-- ---
----
&~M-TFG?~~s
 MAN 'i
k =&W: ZJMD - B&W

50510-02H Cylinder Head, Top Cover Page 2 (2)

Plate

'z1 Qty io-/n=vne~se

Designation

0-ring
Item
No Qly 1 Designation Benawnelse

026 / SIC l Screw Skrue

038 51C l Washer Sk~ve

Top cover Topdzksel

5 cyl. engine 5 c y motor
6 cyl. engine 6 c y motor
7 cyl. engine 7 cyl. motor
8 cyl. engine 8 cyl. motor
9 cyl. engine 9 c$. motor

063 / 8iE /Plug Prop

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs3 side 500.50
= Only available as part of a spare parts kit. = Kun tilg~ngeiigsorn en del af et reservedelss~t.
QtylC = QtylCylinder
QtylC = QtylCylinder
QtylE = QtyIMotor

-- -----
- =a-
--
-
p

p
-
-- -
-
-

c
-

=
-
p

-
-

-
-
-

CBUERATYUC SETS
- - -

0406 98.41- ESO

 ZJMD -
Plate
Page 1 (2) l Cylinder Unit 1 5051 5-04H 1

-- =_=
03.50 - ESO 0406 W
---
- ------- --
F*--=-
GENERATING S E T S
 Plate
50515-02H Cylinder Unit Page 2 (2)

---
-
---
-
c -- ---
-S
_ = 0406 01.1 1 - ESO
Z'FCFR-ATKGT~S
 Indexpage
1(1)
Piston,Connecting Rod and Cylinder 506
Liner i

{Piston, connect~ngrod and cylinder liner sos.cr ( 0 2 ~ )

ISeparation/assembly of piston and connecting rod

, s o s - a l , o ~( ~ l g )
'

land fitting of piston rings

- - -

{Piston 5@6-01.lf;(GZH)
- -
-

[Connectrng rod :so~-crn.rsj ~ 3 E ;

/Criteria for replacment of connection rod big-end
i506-81.66(02)
land
l -
main._
bearing shells !5
_-
-.._ .. . l -- ,
j ~ ~ d r a u ltighten~ng
-
ic
. -
of connecting rod screws '5Q5-Ol.25 f o2H) i
p-

11n-situ inspection o f connecting rod big-end

i586-02.30 ( G 2 H )
ibearinq <
.
. l

1Inspectlon and honing of cylinder liner

. .
' ~ i 0 6 - 0 2 . 3 5( Q 2 W ) ,
I
1
i ~ r i n d i n gof seal face on cylinder liner and cylinder i
'

l lsffi6-01.45(C2H) j
ihead 1
4
~D~srnantl~rig r IOW
of piston and cyl~nderl ~ n e at
loverhaul heicht
506-01.59(82H) 1i

1Piston and connectrng rod

. - . p - - . -. . - - p

/piston and connecting rod 150601-08~ i

l
/cylinder liner
1 " -
150610-03% 1
 ZJMD - E&W

Description 506.01
Page 1 (2) Piston, Connecting Rod and Cylinder Liner Edition 02H

Piston Connecting Rod

The piston, which is oil-cooled and of the composite
type, has a skirt made of nodular cast iron and a
crown made of forged deformation resistant steel. It
is fitted with 2 compression rings and 1 oil scraper
ring in hardened ring grooves.
The connecting rod is die-forged. The big-end has a
horizontal split. The connecting rod and piston are
disassembled together with the cylinder liner, thus
ensuring a large bearing diameter and a low bearing
pressure.

By the use of compression rings with different barrel-
shaped profiles and chrome-plated running sur-
faces, the piston ring pack is optimized for maximum
sealing effect and minimum wear rate.
The piston has a cooling oil space close to the piston
crown and the piston ring zone. The heat transfer,
and thus the cooling effect, is based on the shaker
effect arising during the piston movement. The cool-
ing medium is oil from the engine's lubricating oil
system.
Oil is supplied to the cooling oil space in the piston
through spray hole in the middle of the connecting
rod to the middle of the piston. Oil is drained from the
cooling oil space through ducts situated diarnetri-
cally to the inlet channels.
The connecting rod has bored channels for supply-
ing of oil from the big-end to the small-end.
The big-end bearing is of the bi-metal type coated
with a running layer.
The bearing shells are of the precision type and are
therefore to be fitted without scraping or any other
kind of adaption.
The small-end bearing is of the bi-metal type and is
pressed into the connecting rod. The bush is equip-
ped with an inner circumferential groove, and a
pocket for distribution of oil in the bush itself and for
the supply of oil to the pin bosses.

The piston pin is fully floating and kept in position in

the axial direction by two retaining rings.

U
m
a
m
m
N

S
4
m Fig 1 Piston Fig 2 Connecting Rod
N
m
0
0

~p ~~p
- p-

98.46 - ESO
 506.01 Description
Edition OZH
Piston, Connecting Rod and Cylinder Liner Page 2 (2)

Cylinder Liner

The cylinder liner is made of special centrifugal cast

iron and fitted in a bore in the engine frame. The liner
is clamped by the cylinder head and rests by its
flange on the water jacket.

The liner can thus expand freely downwards when

heated during the running of the engine. The liner is
of the flange type and the height of the flange is
identical with the water cooled area which gives a
uniform temperature pattern over the entire liner
surface. The lower part of the liner is uncooled to
secure a sufficient margin for cold corrosion in the
bottom end. There is no water in the crankcase area.

The gas sealing between liner and cylinder head

consists of an iron ring.

T o reduce bore polishing and lube oil consumption a

slip-fit-type flame ring is arranged on the top side of
the liner.

Fig 3 Cylinder Liner

- - - - --=g
----m-
- -
GZpERATlNC SETS
98.46 - ESO
 ZJMD - B&W

working card SeparationlASSernbly of Piston and Connecting Rod 506-01 .OS

Page 1 (3)
and fitting of Piston Rings Edition 01H

Safety precautions Special tools

Stopped engrne Plate no Item no IVote

Shut-off startrng air
Shut-off coolrng water
Shut-off fuel oil
F Stopped lub. oil clrcul.
Press Blocking - Reset

Description H a n d tools

Separation of piston and connecting rod for Wooden wedge, 2 pieces

inspection orland overhaul.
Assembly of the piston and connecting rod after
inspection orland overhaul.

Starting position

Disassembly of cylinder unit 505-01.01

Related p r o c e d u r e

Inspection orland overhaul of piston, 506-01.l0

lnspection orland overhaul of
connecting rod, 506-01.15
lnspection of connection rod big-end
bearing, 506-01.16
Assembly of cylinder unit 505-01.50

N,
I Manpower Replacement and wearing p a r t s
m'
9
g Working time : 1 hour Plate no Item no QtyICyl.
,S-I Capacity 1 man 50601 093 1
m
N
-,- 5060 1 103 1
50601 127 1

0
Data for pressure and tolerance (Page 500.35)
Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.45- ESO ---

-
--
-W---
- - ---
---
--=

CE4ERATING SETS
506-01-05 SeparationlAssernbly of Piston and Connecting Rod
Edition 01H and fitting of Piston Rings
Separation of Piston and Connecting Rod
l) Take out the securing ring (seeger circlips)
with the plier (Plate 52006, Item 177).Push out
the piston pin and lift the connecting rod away.
Assembly of Piston and Connecting Rod
2) Lubricate the piston pin before assembling.
3) For assembly of piston and connecting rod,
see point l, but in the opposite direction.
Joint pin for
Joint coil spring to be
coil spring
\
\
l I
Fig I Joint coil spring to be placed opposite to ring joint.
working Card
Page 2 (3)
Fittings of Piston Rings
The piston rings should only befitted to the piston by
the use of a special tool; the socalled piston ring
opener.
If the rings are opened further than necessary there
is a risk of overstressing, which means that rings will
become permanently distorted and will not confirm
to the cylinder inner running surface.
The piston rings should be installed with the
identification mark, which is stamped into the ring
close to the ring joints, facing upwords, see fig 2.
Before fitting the coil spring loaded scraper ring, the
c011spring is dismantled from the ring by removal of
thejoint pin. Thecoil spring is placed and assembled
in the ring groove then the scraper ring is fitted in the
groove in such a waythat the ring joint isapproximately
180" offset to the spring joint.
Ascertain correct assembling by checking the back
clea:ance.The back clearance is sufficient when the
face of the ring is below the groove edge when the
ring is pressed against the bottom of the groove.
When installed on the piston the rings should be
pushed back and forth in the grooves to make sure
that they can move freely. It is also advisable to insert
a feeler gauge of adequate thickness between ring
and groove.
Adequate clearance is present so the feeler gauge
can be moved all the way round.
To prevent gas leakage through coinciding ring
joints the piston rings should be turned into positions
offsetting the ring joint 180" to each other.
98.45 - ESO
 / MAN
ZJMD - S&W & B&W F
$t

wowngcard SeparationlAssernbly of Piston and Connecting Rod 506-01

Page 3 (3)
and fitting of Piston Rings Edition 01 H

, No 'tap 1416"

Scraper Ring:
marked with ident.
No "top 0254".

Marking of Piston and Scraper Rings

N
7

m
9
P:"']
'P Marking
3
rD
m
N
I Identification marks to face upwards against the piston crown when mounted.
2
4
a3
N
Note! The marking may include other figures than mentioned above, for instance trade mark and
0
m production codes.
0

Fig 2 Making of piston and scraper ring

 Working Card
Piston 506-01.l
0
Page 1 (3) Edition 03H

Safety precautions Special tools

Stopped engine Plate No Item No Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
m Stopped lub. oil circul.
Press Blocking - Reset

Description Hand tools

Cleaning and inspection of piston. Replacement Tools for cleaning of piston, steel brush,
of piston ring, scraper ring and control of ring scraper etc.
grooves.

Starting position

Piston has been dismantled from

connecting rod 506-01.05

Related procedure

Assembly of piston and connecting

rod and fitting of piston rings 506-01.05

Manpower Replacement and wearing parts

Working time : 1 hour Plate No Item No Qtyl

Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

99.33- ESO
 ZJMD - =&W

506-01.l 0 Piston
Working Card
Page 2 (3)
Edition 03H

I n s p e c t i o n o f Piston Mounting o f Piston C r o w n

l) Remove the piston and scraper rings. 8) Lubricatethe threads and bearing surface with
"molycote-paste G-n Plus".
2) Clean the piston on the outside and on the
inside. Note: always use new bolts when assembling the
piston
3) Inspectthe piston ring and scraper ring grooves
for wear, see page 3. 9) Tighten the bolts crosswise with 20 Nm
(corresponding to 35" to 90").

Check of P i s t o n Bolt Tension 10) Loosen the bolts again.

4) Apply a torque spanner to the piston bolts, ll ) Tighten the boltsagain witha pretighten torque
adjusted to 20 Nm. of 10 Nm.

5) Turn the torque spanner. 12) Turn the bolts 60"further.

Note: It may turn out that the bolts do not turn during 13) Check the piston bolt tension, see ''check of
the test: piston bolt tension".

If 1 Then

The bolts do not The tension are ok

turn during the test

The bolts can Loosen the bolts and

turn during the test tighten as described for
the process of
"Mounting of piston
crown"

I n s p e c t i o n of P i s t o n C r o w n

For cleaning and inspection of the piston crown, it

must be disassembled.

6) Loosen the bolts and removethe piston crown.

7 ) Clean carefully the piston shirt and piston

bolts.

0406 99.33 - ESO

 ZJMD - B&W

Working Card 506-01 .l

0
Page 3 (3) Piston Edition 03H

The piston crow must be scrapped if:

Piston and oil New ring
scraper ring. grooves.
Nominal size. Tolerances.
A) The wear limit on the testing mandrel is (mm) (mm)
exceeded, see fig 1A
Piston ring
1

Piston ring
B) Theclearance between the new pistonlscraper 2
ring and the ring groove is exceeded, see fig
1 B. Scraper r i n ~

Note: At each piston overhaul: Table l . Nomhal size, new ring groove tolerance and wear
- The piston and the scraper ring must be
limit for ring grooves.

replaced.

- The cylinderlinermustbe honedaccording

to the instructions.
- For posifion and fittings of piston rings,
please see working card 506-01.05

A) Testing Mandrel for Ring Grooves B) Clearance Ring!Groove

If the wear limit on the testing mandrel is

exceeded, the specified max. wear limits are
exceeded, and the piston must be scrapped.

Wear limit line.

' Maximum vertical clearance

between new piston ringlscraper
ring and ring groove: 0.40 mm.

The handle is marked

with the nominal size.

Fig l Wear limits for ring grooves.

99.33 - ESO
 Working Card
Connecting Rod 506-01.15
Page 1 (4) Edition 03H

Safety precautions Special tools

Stopped englne Plate No Item No Note

E Shut-off start~ngair
Shut-off cool~ngwater
Shut-off fuel oil
H Stopped lub 011circul
B Press Block~ng- Reset

Description

Cleaning, inspection and test measurement of

connecting rod.

Starting position Hand tools

Connecting rod has been Inside micrometer ( l 4 0 mm).

dismantled from piston 506-01.05 Feeler gauge 0.15 - 0.20 mm

Related procedure

Assembly of Cylinder Unit 505-01.50

Manpower
Replacement and wearing parts
Working time : 112 hour
Capacity 1 man Plate No Item No Qty 1

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

99.33 - ESO 0406 - ----- E

--=== --==
5
CENERATrJc S E ? ~
 506-01.l
5 Connecting Rod Working Card
Edition 03H Page 2 (4)

Cleaning of Connecting Rod Measurement of Big-end Bore

'l) Clean all machined surfaceson the connecting
rod.
2) Degrease thejointfaces, holes and connecting
rod screws with a volatile solvent and blow dry
with working air.
For check of ovalness the bearing cap has to be
mounted onto the big-end bore without bearing
shells.
Note: The ident. No on the connecting rod and the
bearing cap must always be the same, see fig 3.

Visual lnspection of Faces

3) Inspect the joint faces.

Damages, in the form of visible wear marks

and pittings or even cracks, may be in the joint
faces due to relative movements between the
surfaces.

Wear marks and cracks are visible, but not

perceptible with afingemail. Pittings and impact
marks are both visible and perceptible.

Note: Handle the connecting rod with care. In case

of damaged joint faces caused by improper hand-
ling, the bearing cap can no longer be tightened to
the connecting rod without ovalness of the big-end
bore.

4) Register observed damages in the scheme

"Connecting Rod Inspection" for historic use
only. Please see page 4. Fig 7 Point of measurement

5 ) Carefully smooth single raised spots in the

serration caused by pitting and impact marks 8) Mount the bearing cap onto the connecting rod
with a filesmall. by means of the connecting rod bolts.

Inspection of Connecting Rod bolts 9) Tighten the bolts with the prescribed pressure,
please see working card 506-0 1.25.
6) lnspect the connecting rod nuts for seizures in
the threads and pittings on the contact surfaces 10) Measure five different diameters in the groove 2
m
of the screwheads. of the boring, see fig 1. 9
+.
2
7) Turn the connecting rod nuts onto bottom l'l) Register the measurements in the scheme
LD
position of.the bolts. "Connecting Rod Inspection". Pleaseseepage
4. n
If boltslnuts Then 2
N

12) Calculate the maximum ovalness as the diffe- g

have seizures in Renew the boltslscrews rence between biggest and smallest diameter
threads or pittings on measured
contact surface
13) Check if maximum ovalness is exceeded,
cannot be turned onto Renew the boltslscrews please see page 500.35.
bottom position by hand
----
L
P-
CE-TNC
-S==
-
SETS
0406 99.33 - ESO
 ZJMD - B&W

Working Card
Connecting Rod 506-01. l 5
Page 3 (4) Edition 03H

If Then Forconnecting rod No2 in the example the maximum

I ovalness is 0.125 mm and therefore the connecting
maximum ovalness is Renew the complete rod is rejected.
exceeded connecting rod, screws
and bearing shells.
lnspection of Connecting R o d Bush
maximum ovalness is
not exceeded I Reuse the connecting rod
14) Inspect the surface of the piston pin and the
connecting rod bush.

15) Measurethe clearance between the piston pin

and bush.
( Connecting ~ o Inspection
d for L16124
I Check if max clearance is exceeded, seepage
16)
500.35.

If the specified clearance is exceeded, contact

MAN B&W DieselAIS, Holebyforreplacement.

lnspection o f Bearing Shells for Big-end

Criteria for replacement of connecting rod big-end

bearing, see working card 506-01.16.

Max warners = 0.05 mm

Nole! The @dentNo on ttr mn-

nedinp rod am m ttr beanng

Fig 2. "Connecting rod lnspection"

Example of Measurement Results

N
7

m
p The example, see fig 2, shows measurements and
cr
damage observationsfor two connecting rods on the
S
scheme "Connecting Rod Inspection" (in case the
U,
F specified maximum ovalness is exceeded, contact
Q

0 MAN B&W Diesel N S , Holeby for overhaul).

cb Fig 3 The ident No on the connecting rod must always be the
N
0 same.
CO
o Forconnecting rod No 1 in the example the maximum
ovalness is 0.07 mm and thus reuse is acceptable.

99.33 - ESO 0406 - -----=F=--==

-
5
m-

CENEFSTWG SETS
 q,:rS7.:>:&.
A$? */
P U,.

ZJMD- B&W

506-01 .l 5 Working Card

Edition 03H Connecting Rod Page 4 (4)

=
-p
-- ---
--- ---
---- 0406 99.33 - ESO
Z-rK5ZET~s
 ZJMD -
Working Card Criteria for Replacement of 506-01 .l
6
Page I (5) Connecting Rod Big-end and Main Bearing Shells Edition 02

Safety precautions: / special tools:

Stopped engine Plate no. ltem no. Note.

E Shut-off startlng air
E Shut-off cooltng water
C Shut-off fuel o ~ l
E Shut-off coolrng orl
E Stopped lub or ctrcul

Description:
Inspection of bearing shells.
Hand tools:

Magnifier (x30)

Starting position:

Bearing shells removed from engine:

Big-end bearing, 506-01.30
or
Main bearing and guide bearing 510-01.05

Related procedure:
Mounting af bearing shells:
Big-end bearing, 506-01.30
Main bearing and guide bearing 510-01.05

Man power: Replacement and wearing parts:

Working time : 114 hour Plate no. Item no. Qty. /
Capacity 1 man

Data:
Data for pressure and tolerance (Page 500.35)
Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

02.26 - ESO 0406

506-01.l
6 Criteria for Replacement of Working Card
Ed~tion02 Connecting Rod Big-end and Main Bearing Shells Page 2 (5)

This paper gives information about the evaluation of Bearing S u r f a c e

the connecting rod big-end and main bearing shells
when wear appears on the running surface under Standard Miba bimetal bearings have no tin flash.
normal operat~ngconditions.
Oil is used for protective coating.
Bearing damages caused by incorrect running con-
ditions, like In new condition the bearing has a silvery, bright
color.
- Corrosion
- Overloading, overheating a.s.0. The running surfase might become dull silvery after
only a shori time of operation.
are not described in this paper

In these cases, the bear~ngshells must be exchan- Criteria f o r b i m e t a l b e a r i n g r e p l a c e m e n t

ged, of course, and in order to avo~dfurther bearrng
failures, the cause of the farlure must be found and
el~m~nated.
New C o n d i t i o n
The running surface has a silvery, bright color, see
fig l.
Actua! wear can be determined by measuring wall
thickness or via clearance measurements in
comparison to the specification for a bearing in new
condition.
A bearing should be replaced if the wear limit, as
specified by the engine manufacturer, is reached or
can be expected to be reached during the next
period of operation.

Another method is to specify a certain time limit for

the useful service life of the bearing. The individual
time limit (recommended maximumtime in operation)
specified by the engine manufacturer is based on the
calculated bearing load, minimum oil film thickness
and load profile.

The useful service lifeofa bearing is alsodetermined

bythefatigue strength ofthe lining material underthe
respective load profile.

Usual r u n n i n g p a t t e r n
Fig 1 Without flash
Typical running pattern after completion of running-
in: N
7

m
a

0406 02.26 - ESO

 Workins Card Criteria for Replacement of ! 506-01.16 !
p a g e (5) Connecting Rod Big-end a n d Main Bearing Shells Edition 02
l

Bearings to be reused 3. Damage due t o foreign particles

Following pictures shows the typical running pattern Shallow scoring and I or imprints that are few in
where bearing shells are reusable. number. See fig 4.

l. Normal wear

Slightly polished zones and symmetrical running

pattern in the most loadedzone ofthe bearing. Minor
scoring. See fig 2.

F@ 4 Reusable

4. Minor cavitation after long time in operation

Minor and shallow material removal outside the most

~igP Reusable loaded zone. See fig 5.

2. Minor edge loading

and usual running pattern.

Slightly polished stripes along the side faces. See
f7g 3.

~ ; 5g Reusable

fig3 Reusable

02.26 - ESO 0406

1 MAN
=&W.
"ac

ZJMD - B&W

506-01.l
6 Criteria for Replacement of Working Card
Edition 02 Connecting Rod Big-end and Main Bearing Shells Page 4 ( 5 )

Bearings to be replaced 7. Damage due to foreign particles

Followingpicturesshowsabnormalwearordamages Many scores or multiple deep grooves and 1 or

that require replacement of bearing shells i.e. imprints. See fig 8 and fig 9.
investigation of reasons.

5. Localized heavy smearing of lining material

due to local disturbance of the oil film. See fig 6.

Fig 8 Replace
- deep scoring. imprints Lining material locally smeared

Fig 6 Replace

6. More extensive area of damage with seizure

Locally smeared lining material

caused by a severe disturbance of the oil film. See

fig 7.

~ i 9g Replace
- many deep imprints

F@ 7 Replace

0406 02.26 - ESO

 ZJMD - 13&W

Working Card Criteria for Replacement of 6

506-01.l
Page 5 (5)
Connecting Rod Big-end and Main Bearing Shells Edition 02

8. Deep punctual cavitation 10. Fatigue rupture of the lining material

In severe cases the cavitation extends to the steel Mechanism:

shell, spreads along the interface between steel - Development of fine cracks in the lining
shell and lining material, and undermines theAlSn20 material
lining. See fig 10. - Network of cracks (crazing)
- Parts of the lining material break out

~ i 10
g Replace
FI_O
12 Fatigue rupture

9. Deep cavitation

Cavitation at the end of the oil groove.

.-
rn
$- Fig17 Replace
m
N
- deep cavitation
0
m
0

02.26 - ESO 0406

 ZJMD - B&W

Working Card
Page I(2) Hydraulic Tightening of Connecting Rod Screws 506-01.25
Edition 02H

Safety p r e c a u t i o n s Special t o o l s

Stopped engine Plate No Item No Note

m Shut-off starting air
Shut-off cooling water 52021
Shut-off fuel oil 52021
E Stopped lub. oil circul. 52021
Press Blocking - Reset 52021
52021
52021
52021
Description 52021
Tightening procedure for connecting rod bolts.
Check of connecting rod bolts, tightening condit-
ion.

Hand tools
Starting p o s i t i o n

Piston, connecting rod, bearing shells and

bearing cap preassembled

I Related p r o c e d u r e

Manpower Replacement a n d wearing parts

Working time : % hours

Capacity 2 men

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

99.33 - ESO
-=-z -
---
----A
c-
---
-=-=

GENEFXTINC SETS
 506-0'.25 Working Card
Edition 02H
Hydraulic Tightening od Connecting Rod Screws Page 2 (2)

I) Mount the connecting rod bolts and tighten the
nuts by hand.
2) Mount the hydraulic tools, pos. I, on both
connecting rod bolts.
Be aware of the max. lifting height of the tool
and adjust the distance between the piston
and the cylinder before adding pressure to the
tool. please see working card 520-01.05.
3 ) Connect the hoses and pressure pump to the
hydraulic tool.
4) Add the prescribed hydraulic pressure, (to
both bolts simultaneously), see descripfion
500.40, and tighten the nuts by using a handle.
5) Relieve the hydraulic pressure on the tool.
6) Add the hydraulic pressure to the tool once
more.
7) Tighten the nuts again.
Note: The point 5 to 7 can be followed in order to
remove tensions in the bolts, if any.
8) If there still is a distance and the nuts still can
be tightened then repeat the point 5 to 7.
9) Release the hydraulic pressure on the tool and
remove the hydraulic nuts.
Note: General instruction about hydraulictightening,
please see working card 520-0 1.05.

1. Hydraulic tools

Fig I Hydraulic tool for tightening of connecting rod screws

-- ----
----
m
---
===
E M R A T I N G SETS
99.33 - ESO
 ZJMD - B&W

,,,,, In-situ lnspectioan of Connecting Rod Big-end Bearing 506-01.30

Working Card
,,( EdilionmH

Safety precautions ' Special tools

@ Stopped englne Plate No ltem IVo Note

Shut-off start~ngair
Shut-off cool~ngwater
Shut-off fuel 011
E Stopped lub oil circul.
Press B ~ O C -KReset
I~~

Description

In-situ inspection andtor replacement of

connecting rod big-end bearing.
Dismounting and mounting.

Starting position Hand tools

Crankcase opened. Open-end spanner 24 mm

Related procedure

Inspection of connecting rod

big-end bearing 506-01.16
Tightening and check of connecting
rod screws 506-01.25

Manpower Replacement and wearing parts

Working time : 1 'l2hours Plate No Item No Qtyl

Capacity 1 man
.
I
L3
4
m
N
-
D
m
0
1 Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.38- ESO =- -----

--
-
-=
-- -=
='-
L=-
-=

-ERATWO
-P

SETS
---
 506-01.30 ln-situ Inspection of Connecting Rod Big-end Bearing Working Card
Edition 02H

I) Turn the crankshaft into the top position. 7) Slowly turn the crankshaft clockwise until the
connecting rod is resting on the inspection
tool.
Removal of the Connecting Rod Bearing
Cap
Removal of t h e u p p e r Connecting Rod
2) Loosen the hydraulic bolts by means of the Bearing Shell
hydraulic tools, please see working card 520-
01.05. 8) Mount the connecting rod on the inspection
tool by means of the connecting rod bolt and a
3) Remove the hydraulic tools. nut.

4) Remove the hydraulic nuts and the bearing Note: Make sure that only one connecting rod bolt is
cap with the lower bearing shell by hand. fit in the connecting rod before the crankshaft turns
any further.

Mounting of t h e Inspection Tool 9) Turn slowly the crankshaft clockwise until it is

possible to remove the upper connecting rod
5) Turn the crankshaftapp. 45~lockwiseallowing bearing shell.
the connecting rod bolts be removed.
10) Remove the upper connecting rod bearing
6) Mount the inspection tool acc to fig I. shell.

l l
Fig I Mounting of the inspection tools.

--
E
----
-- -S
---------
~ - T % ? T I ~ ~ S
0406 98.38 - ESO
 ZJMD - B&W
7

Working Card 506-01.30

,,,,,,,, in-situ lnspection of Connecting Rod Big-end Bearing EditionOLH

Inspection of Bearing Shells 16) Turn slowly the crankshaft anti-clockwise until
it rests in the connecting rod.
11) lnspectthe bearing shells, pleasesee working
card 506-07.76. 17) Remove the inspection tool.

Cleaning of Components before Mounting Mounting of Bearing Cap

12) Clean carefully the joint faces, the bore and the 18) Lubricate threads and contact face of the
bearing shells. connecting rod bolts with Copaslip or the like.

19) Mount the connecting rod bolts.

Mounting of Upper Bearing Shell
20)
13) The bearing shell is placed in the bore, the
contact surfaces of the shells must be parallel
to the contact surface of the connecting rod 21)
and the bearing cap respectively.
Turn the crankshaft anti-clockwise until it is in
the top position.
Mount the bearing cap with the inserted lower
big-end bearing shell by hand.

14) Coat the journal with clean lubricating oil. 22) Mount the screws and tighten them by hand

15) Remove the bolt and nut from the connecting 23) Mount the hydraulic tool and tighten the bolts
rod and inspection tool. according to working card 506-0 1.25.

98.38 - ESO
 MAN ''v
1; =&W ;

Working Card
lnspection and Honing of Cylinder Liner
506-01.35
Page 1 (4) Edition 02H

Safety precautions Special tools

Stopped engrne Plate No Item No Note

Shut-off starting air
Shut-off cool~ngwater
Shut-off fuel oil
Stopped lub. oil c~rcul.
I? Press Blocking - Reset

Description Hand tools

lnspection and honing of cylinder linerwith honing Drilling machine 60-180 rpm.
brush. Honing oil.
Gas oil.

Starting position

Piston and connecting rod

removed 506-01.01

Related procedure

Grinding of seal face on cylinder

head and cylinder liner 506-01.45

Manpower Replacement and wearing parts

Working time : 112 hour

Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

99.33- ESO
 ZJMD - =&W

506-01.35 Inspection and Honing of Cylinder Liner

Working Card
Edition 02H Page 2 (4)

M e a s u r e m e n t of C y l i n d e r Diameter Honing the Cylinder Liner

While the piston is removed from the cylinder, the
latter is measured to record the wear. The measure-
ments are taken by means of an inside micrometer,
with measuring pointsat TDC-position forthe upper-
most piston ring, halfway down, and at the bottom of
the cylinder liner, see fig l and page 4.
Renovation is made in the workshop.
Priorto honing, deposits of coke and possible wear
edges at the top of the liner must be removed by
scraping.
A used flame ring must be used during the honong
process.

The used flame ring must be cleaned in water.

Subsequently, the flame ring is remounted in the
cylinder before carrying out the honing process.

4 80-1 60 rpm.

s
Fig 1 Measuring points.

The measurements should normally be taken in both

transverse and in longitudinal direction

When measuring, take care that the measuring tool

has approximately the same temperature as the Fig 2 Flex-honer in cylinderliner.
liner. When the wear of a cylinder liner exceeds the
value indicated on page 500.35, i.e. when it becomes
too troublesome to maintain adequate service con- Note: Upon completion of the honing process the
.
p:
m

g
N
ditions, the cylinder liner in question should b e used flame ring is discarded. A new flame ring is
F
replaced. always mounted in the cylinder when replacing the o
piston rings. 2
N
0
m
0

--
E m F
m -v---
-=-
- ---
-
GENEWTNC SETS
 Working Card 506-01.35
Page 3 (4) Inspection and Honing of Cylinder Liner Edition 02H

The honing is made by means of a flex-honer with

grain fineness 80-120. A revolution speed between
80 and 160 rpm is chosen.

In orderto achieve a required angle between honing

grooves, see fig 3, the vertical speed is adjusted to
about 1mlsec. which corresponds toabout 2 sec. for
one double movement (the flex- honer is led from
below up and down in 2 sec.)

The procedure must be continued until the cylinder

wall is covered by honing grooves and the surface
has a slight matt appearance without any signs of
glaze. Fig 3 Angle b e t ~ e e nhonivggrooves

During the honing it is important to lubricate freely

with honing oil or cutting oil.

After the honing, the liner is carefully cleaned with

gas oil. Make sure that all abrasive particles are
removed.

99.33 - ESO ----

----M

CZ-TINC
Te-=--
T=
SETS
-
 ZJMD - S&W

506-01.35 Working Card

Edition 0 2 ~ Inspection and Honing of Cylinder Liner Page 4 (4)

99.33- ESO
 ZJMD - EBW

Workrng Card Grinding of Seal Face O n 506-01.45

Page I(2) Cylinder Liner and Cylinder Head Ed~tion0 2 ~

Safety precautions Special tools

Stopped engine Plate No ltem No Note

H Shut-off start~ngair
F Shut-off cool~ngwater 52005 087
Shut-off fuel 011
Stopped lub. oil circul.
Press Blocklng - Reset

Description Hand tools

Grinding of seal face on cylinder liner, cylinder Grinding pasta

head and cylinder crankcase by hand with grin-
ding tool and grinding pasta.

Starting position

Disassembly of cylinder unit 505-01.01

R e l a t e d procedure

Assembling of cylinder unit, 505-01.50

Manpower Replacement and wearing p a r t s

Working time : % hour Plate No ltem No Qtyl
Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.38 - ESO
 ZJMD - B&W

506-01.45 Grinding of Seal Face o n Working Card

Page 2 (2)
Edition 02H Cylinder Liner and Cylinder Head

Note: The grinding tool is used for both grinding the

groove in the cylinder liner flange (l),
the surface of
the cylindercrankcase (2) and the sealing surfaceon
the cylinder head (3),see fig. I.

2 Crankcese
Fig 3 Grinding tool at cylinder crankcase

Fig. l Grinding tool

l) Loosen the sealing ring in liner flange and take

it out.

2) Face-grind the sealing grooves in the cylinder

liner flange, see fig. 2, the surface of the
cylinder crankcase, see fig. 3 and the sealing
surface on the cylinder head, see fig. 4 with
the use of grinding pasta and the grinding tool.

Fig 4 Grinding tool at cylinder head

3) Move back and forth the tool and lift it out from
time to time.
(\I

4) After grinding , remove carefully all traces of

abrasives and grinding compound. 9
*
S
5) When having groundthecontactfaces between 3
cylinder head and cylinder liner it must be
observed that the sealing minimum heighth 2
above the cylinder liner is according to500.35.
g
m
0

Fig 2 grinding tool at cylinder liner

98.38 - ESO
 Working Card Dismantling of Piston and Cylinder Liner 506-01.5Q
Page 1 (2)
at Low Overhaul Height Editron 0 2 ~

Safety p r e c a u t i o n s Special tools

I% Stopped engine Plate No ltem No Note

Shut-off starting air
&i Shut-off cooling water
H Shut-off fuel oil
Stopped lub. oil circui.
B Press Blocking - Reset

/ Description
l Hand tools
Dismounting of cylinder unit for inspection andlor Inside micrometer ( l 95 mm)
overhaul. Feeler gauge 0.15 - 0.20 mm

1I
Starting p o s i t i o n

Engine stopped and cooled down.

l
Related procedure

Inlet and exhaust valve - overhaul and

regrinding of spindel and valve seat, 505-01.10
Valve rotator, 505-01.l5
Replacement of valve guide, 505-01.20
Replacement of valve seat ring, 505-01.35
Inspection of piston, 506-01.10
Cylinder liner 506-01.35
Separation of piston and
connecting rod 506-01.05
Fuel injection valve 514-01.10

Manpower Replacement a n d w e a r i n g p a r t s

Working time : 2 'l2hours Plate No Item No Qtyl

Capacity 2 men

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

99.33- ESO
 ZJMD - B&W

506-01.50 Dismantling of Piston and Cylinder Liner Working Card

Page 2 (2)
Edition 0 2 ~ at LOW Overhaul Heights

Removal of Cylinder head Removal of Water Jacket, Cylinder Liner,

l ) Prepare removing of the cylinder head
according to working card 505-01.55pos. I to
15.
2) Remove the bolts which hold the cylinder head
and water jacket together.
Note: This means that the cylinder head now can be
removed from the cylinder unit.
Piston and Connectinng Rod
5) Removethe bearing cap and mount the tool to
suport the connecting rod to the cyl. liner,
please see working card 505-01.55
6) Lift carefully the waterjacket, cylinder liner and
piston with connecting rod just enough for
removing the upper connecting rod bearing
shell.

3) Mount the lifting tool on the cylinder head. 7) Lift carefully the waterjacket, cylinder linerand
piston with connecting rod out of the engine
4) Lift the cylinder head and land it carefully in and land them on wooden support.
wooden support.

Note: The push rods will fall out if they are not
supported by hand.

99.33 - ESO
 I Plate
Page 1 (2) Piston and Connecting Rod

98.09 - ESO 0406 -- --

--
7
- - --
=-S5
m ---m- - E=-
-

GMRATYUC SETS
 ZJMD - 6&W

Plate
50601-03H Piston and Connecting Rod Page 2 (2)

/
l
Q
, 1
l
Designation Benavnelse
Item l
No
l
Q
, 1
l
Designation Benavnelse

019 ( l1C 1 Piston pin Slernpelpind 1l il

032 ( 21C
l Reta~nlngring Sikringsring

/
I
l1C / Bush for connecting Plejlstangsbosning
1 rod
l

068 ) l/C I Connecting rod 212 Plejlstang 212

l
081 1 l/C l Piston 2R, Stempel 212,
j / incl. item 176 inkl. item 176

093 1 / IIC
I
Piston ring Sternpelring

103 1 1 l1C Piston ring Sternpelring

127 1 1 IIC Oil scraper ring Olieskrabering

Plejlstangsleje 212
bearing 212

140 2lC /Cylindrical pin Cylindrisk stifl

for connecting Plejlstangsskrue

Mothk
1

176 ( 4lC l Bolt Bolt

l j
I j

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se o g s i side 500.50.
= Only available as part of a spare parts kit. = Kun tilgzngelig som en del af et reservedelsszt.
QtylC = QtylCylinder. QtyIC = QtylCylinder.

98.09 - ESO
 ZJMD - B&W

Plate
Page 1 (2) Piston and Connecting Rod 50601-08H

01.32 - ESO 0406 v- ----

- -----
=S=
- - - - - m
===-
=
GENERATING SETS
 Plate
50601-08H Piston and Connecting Rod Page 2 (2)

E': l
~ t yDesignation Benaevnelse

Stempelring

103 ) IIC 1 Piston ring Sternpelring

127 1 1IC 1 Oil scraper ring Olies4rabe:ing

I I
13' ) 11C Connecting rod
1 bearing 212
212
Plejlstangs~e~e

140 1 2lC l Cylindrical pin Cylhndr~sks t f

152 2lC (Screw for connecting Piejlsti-n~rriiue

l
164 2lC / ~ u t Matrik

223 1 1/C 1 Piston 212, Sternpel 212,

1 1 incl. item 259 inkl. item 250

235 I IIC
I

/
l
Piston pin Sternpelpind

247 1 2lC
i
Retaining ring Sikringsnng

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele,se ogsa side 500.50

Only available as part of a spare parts kit. = Kun tilggngelig sorn en del af et reservedelss~t.
QtylC = QtylCylinder. QtyIC = QtyICylinder.

0406 01.32 - ESO

 c"Ai,,p~z~w%s+
{.>%'
'"
",
%*D

\$
:IMAN :;
ZJMD - B&W [, B & W ;

Plate
Page 1 (2) Cylinder Liner 50610-03H

97.07 - ESO OQOG -- ---

--
E
- ----
---&-=
-m----

GENERATING SETS
 50610-03H Cylinder Liner Page 2 (2)
Plate

Item 1
No Qty 1 Designation Benzvnelse
Item
No
(
Qty 1 Designation 6en;evnelse

018 1 l/C
l
Cylinder liner Cylinderforing

031 1 IlC 1 Sealing ring Tzetnjngsring

092 / l/C Flame ring Flanmering

! I

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsi side 500.50
= Only available as part of a spare parts kit. = Kun tilg~ngeligsom en del af et reservedelssa3t
.- QtylC = QtylCylinder. QtylC = QtylCylinder.

- - ----
--
--
E
-- --- -
S=--&

CBVERAThG SETS
97.07 - ESO
 ZJMD - B&W
1
?
;;
:h 1 Camshaft and Camshaft D n ~ e I 507 1
/ c a m s h a f t and c a m s h a f t drive ~ ~ Q ? . G(L6 2 ~ )

,
p---
-
-
p----p-

,Check of C a m s h a f t a n d c a m s h a f t d r ~ v e 5 Q l - t J l . O C [@2H)
---p
--p- - -

i I n s p e c t ~ o nand r e p l a c e m e n t of camshaft bearing 507-GL.05(05H)

-
--P-
-
-
/Adjustment of c a m s h a f t for valve a n d injection I !
jtirning
iso7-c1.rc {os~-r:i

,Intermedrate wheel 5G7CT-G2!4

;Camshaft (valve c z m s h a f t ) 5C705-03s
- -

;Camshaft (Injection c a m s h a f t ) 507~5-~45 l

 ZJMD - B&W

Description 507.01
Page 1 (1) Camshafts and Camshaft Drive Edition 02H

Camshafts and Camshaft Drive The camshafts are located in bearing bushes which
are fitted in bores in the engine frame; each bearing
The inlet and exhaust valves as well as the fuel is replaceable and locked in position in the engine
pumps ofthe engine are actuated by two camshafts. frame by means of a locking screw.

Due to the two-camshaft design an optimal adjust-
ment of the gas exchange is possible without inter-
rupting the fuel injection timing. It is also possible to
adjust the fuel injection without interrupting the gas
exchange.
The gear wheel for driving the camshaft as well as a
gear wheel connection for the governor drive are
screwed on to the aftmost section.

The two camshafts are located in the engine frame.

On the exhaust side, in a very high position, thevalve
camshaft is located to allow a short and stiff valve
train and to reduce moving masses.

The injection camshaft is located at the service side

of the engine.

Both camshafts are designed as cylinder sections

and bearing sections in such a way that disassembly
of single cylinder sections is possible through the
side openings in the crankcase.

The two camshafts and the governor are driven by

the main gear train which is located at the flywheel
end of the engine. They rotate with a speed which is
half that of the crankshaft.
Fig l Twin camshats, seen from flywheel end
 MAN
ZJMD -/eEkw\
Working Card
Check of Camshaft and Camshaft Drive 507-01 .OO
Page 1 (2) Edition 02H

Safety p r e c a u t i o n s Special tools

@ Stopped engine Plate No Item No Note.

B Shut-off starting air
0 Shut-off cooling water
0 Shut-off fuel oil
Stopped lub. oil circul.
Press Blocking - Reset

Description 1
l
Checking of gear wheels, bolted connections and Hand tools
lubricating system.
Unbraco top, 8 mm
Ratchet
Extension
Top, 24 mm
Starting p o s i t i o n Serrated fork

Related p r o c e d u r e

Man power Replacement and wearing p a r t s

Working time 3 Hours Plate No Item No Qty .l

Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.38 - ESO
 Working Card
Edition 02H
Check of Camshaft- and Camshaft Drive Page 2 (2)

1) Dismount the covers which give access to the
gear wheels, camshaft and crankcase.
2) Examine all gear wheels for cracks, wear and
deformations. While turning the engine to
enable inspection allover the circumference of
the gear wheels.
3) Check all screws, nuts and bolted connec-
tions, including locking devices everywhere in
thegearwheel housing, camshaft housing and
crankcase to check that they have not worked
loose. Tightening torques, please see page
500.40.

4) Start the electrical prelubricating oil pump and

check the oil flow from bearings.

5) Mount the covers.

98.38 - ESO
 Working Card
Inspection and Replacementof Camshaft Bearing
507-01.05
Page 1 (3) Edition 05H

Safety precautions Special tools

Stopped engine Plate no Item no Note.

Shut-off start~ngair
Shut-off cooling water
Shut-off fuel oil
Stopped lub 011circul
Press Block~ng- Reset

Description Hand tools

Check of roller path of cams and check of cam-
shaft bearing.
Replacement of camshaft bearing.

Starting position

Cover for camshaft and gear wheel has been

removed.

Related procedure

Camshaft and camshaft drive. 507-01 .OO

Man power Replacement and wearing parts

Working time 2 Hours Plate no Item no Qty. 1
Capacity 2 men

Data
Data for pressure and tolerance (Page 500.35)
Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

01.08 - ESO
 507-01m05 Inspection and Replacement of Camshaft Bearing Work~ngCard
Page 2 (3)
Edlbon 05H

To Check Roller Path of Cams

l) While turning the engine, examine the cam

discs and in particular, check the roller path of
all cams for cracks, crackles and ruffle. Also
examine the rollers of the roller guides.

Note: if there are flat spots on the roller and if some

of the rollers may be blocked, the roller must be
replaced by a new one, please see working card
508-01.00.

To Check Camshaft Bearings

2j 'The wearing surface of the camshaft bearings

cannot be checked without dismounting the
camshaft. However, abnormal wear oi one or
more bearings will become apparent in the
form of burrs of white metal at the circumference
of the camshaft journal, and in that case the
bearing will in no doubt be discoloured, as well.

The bearing clearance is measured with a dial

gauge, please see data sheet 500.35.
Fig 1 Removing of spur wheel and the bearing plate.

To Replace Camshaft Bearing for Injection Pull the disconnected sections of the camshaft
o r valve camshaft so far aft that the bearing which is to be
re~lacedis free.
If one or several of the camshaft bearings should be
replaced, the camshaft must be wholly or partly 6) Remove the spur wheel and the bearing plate,
dismantled. see fig I so the camshaft can be moved toward
the generator.
Note: Before dismantling last bearing and spur gear
wheel the engine has to be turned so marks at gear 7) Push the bearing out of the bore in the engine
wheels are corresponding, please see Working frame.
Card 507-01.20. Engine must be locked in this
position. 8) Check the lubricating oil ducts to the bearing
N
for free flow. 7

m
3) The camshaft sections are marked in relation 9
to each other. 9) For fitting of the bearing it must be cooled down
with CO, to -90°C below crankcase tempera-
5
m
r
Nn
4) Disassemble the camshaft for (toward engine ture.
front) of the bearing that is to be replaced.
W
10) Inspect the camshaft journal for seizures. N
0
(0
5) Dismount all .roller guides that are located aft of 0
the disassembling position,pleasesee working If necessary, the camshaft section must be
card 508-01.00. entirely removed from the engine, and the
journal concerned must be polished.

- ------
-- --
Gl-TIN=
.-m5
SETS
01.08 - ESO
Working Card 507-01.OS
Page 3 (3) Inspection and Replacement of Camshaft Bearing Edition 05H

11) Coat all the journals of the camshaft section

with clean lubricating oil and push the camshaft
into position, making sure that the marks on
the flanges coincide.

12) Assemble the sections and fit the bolts (coated

with molycote or similar).

13) Tighten the nuts with a torque spanner, please

see data sheet 500.40.

14) Mount all roller guides

-- --
------
~-ul rnr
G-:TIN:, SETS
 of Camshaft forvalve and Injection Timing 507-01.20
Working Card
Edition 05H ,

Safety precautions Special tools

Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cooling water 52007 01 5
Shut-off fuel oil
Stopped lub. oil circul
Press Blocking - Reset

Hand tools
Description

Nominal adjustment of camshaft. (Adjustment of

camshaft in relation to crankshaft).

Starting position

1 Camshaft assembled as pertiming order, mounted

in frame and roller gear house.
If intermediated gearwheel must be changed, the
generator must be dismounted.

Related procedure

CV
r
Manpower Replacement and wearing parts
a5
9
*
m Working time : - hours Plate no Item no Qtyi
5
LD
CV
Capacity - man
m
I
0
4
a3 Data
CV
0
0
a3
Data for pressure and tolerance (Page 500.35)
Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

01.08 - ESO
 507-01s20
L A i t i n n nqu )
Adjustment of CarnshaftforValve and injection ~ i r n i n, , ,~, ,a, ( Working Card

Assembly of gear wheels for valve camshaft

a n d Injection valve camshaft, without
mounted flywheel

Following description is for mounting the gearwheels

Upper
in the control drive when alternator, flywheel and intermediate
cover on coupling side are dismantled from the spur wheel
engine.

Mounting of intermediate gearwheels

1) Turn the crankshaft to top dead centre for the

last cylinder (the cylinder nearest to the
coupling side).

2) Mount the upper intermediate gearwheel.

Mount the lower intermediate gearwheel so

the marks on the lower intermediate gear-
wheel are corresponding with the mark on the
crankshaft gearwheel, see fig l(E2). At the
same time turn the upper intermediate gear-
wheel so that the small holes in the circumfer-
ence of the two intermediate gearwheels are
corresponding, see fig 2.
Fig 2 Posifion ofsmall holes m the circumference of the two
Note: The punch mark on the crankshaft gearwheel intermediatedgearv~heels
is placed on the 13 teeth counting counter clockwise
from the joint of the gearwheel, see fig 3.

Fig 3 13 teeth counter-clockwise from the joint of the gear-

wheel
Fig 1Marhs on gearwheels

--- --f
-
-L- 01.Q8- ESO
G:-TINC SETS
 Working Card
Adjustment of Camshaft for Valve and Injection Timing
507-01.20
Page 3 (4) EditionOSH

4) Tighten up the intermediate gearwheels. Tight- Adjustment of fuel lnjection Camshaft I In-
ening torque, please see page 500.40. jection Timing

1) Unscrew both plugs on the sides at the fuel

Mounting of gearwheel for valve camshaft pump for cylinder no 1. Cylinder numbering,
please see page 500.1 1.
5) Before mounting the gearwheel, must marks
for crankshaft and lower intermediate gear- 2) Turn the engine to approx. 20" before ignition
wheel correspond, see fig l(E2). Secondly top dead centre for cylinder no 1.
must the small holes for both intermediate
gearwheels be corresponding. Clean the pressure area of the pump carefully
from fuel by blowing out with pressurized air.
6) Turn the valve camshaft, until the mark on the
gearwheel for valve camshaft corresponds
with the 2 marks on upper intermediate gear-
wheel, see fig 1 ( E l ) .

7) Tighten up the gearwheel. Tightening torque,

please see page 500.40.
?t>cieda'ea carelully
l a a r d Irunituel

Mounting the gearwheel for injection cam-

shaft

8) Before mounting the gearwheel, must marks

for crankshaft and lower intermediate gear-
wheel correspond, see fig l(E2). Secondly
must the small holes for both intermediate
. gearwheels be corresponding.

9) Turn the injection valve camshaft, until the

mark on the gearwheel for valve camshaft
correspond with the 2 marks on upper interme-
diate gearwheel, see fig 1 (El).

Note: Adjustment of injection valve camshaft is now

needed, please see separately chapter "Adjustment
of Fuel lnjection Camshaft / lnjection Timing".

Fig 4 Use a flashlight and a mirror to light through the pump

--

01.08 - ESO
 Z J M D ,c+
507-01.20 Adjustment of Camshaft forvalve and Injection Timing Working Card
Editim 05H ,
,,,
,,!

3) Place a lamp and a mirror in front of the holes
as shown in fig 4.
4) Look through the pump from one side and at
the same time turn the engine in its normal
directions until the plunger in the barrel cuts off
the light from the flashlight on the other side.
Note: Check the stamp on the flywheel. This must
b e according to fig 5.
6) Check injection timing from step 2.
7) If timing of the fuel camshaft is OK, then tighten
the bolts on the gearwheel. Tightening torque,
please see page 500.40.
8) Tighten up the plugs. Tightening torque, please
see page 500.40.

5) If re-adjustment of the camshaft is needed,

then loosen the gearwheel and adjust (tighten
one bolt).

Pump type: Woodward L'Orange

I

Engine rpm 1000 1200 1000 1200

I Light method (E) / 5.5' t 0.5 BTDC 18.6' f 0.5 BTDC ) 9.8' f 0.5 BTDC 112.7. f 0.5 BTDC /
Flywheel circumference
mm1° (3079 : 360) 8.55 8.55 8.55 8.55

- m m (8.55 X Qty.") 47k4mrn 74k4rnrn 84~4mm 1 0 9 k 4 mm

Fig 5 Stadc injection timing

01.08 - ESO
 Plate
Page 1 (2) , Intermediate Wheel

01.43 - ESO 0406 -- ----

----
-- - --
--
- m - -

- ---
-
E~k-~~iTtcTiis
 MAN
; E3&W t

Plate
50701-02H Intermediate Wheel Page 2 (2)

1 Qty /
l
Designation Bencevnelse Qty ) Designation Ben~vnelse

012 1/E Stepped spur gear, Tandhjul, komplet

complete incl. item inkl. item 024, 048,
024, 048, 061 06 1

024 1 1/E Spur gear Tandhjul

036
i l
1/E Spur gear, complete Tandhjul, kornplet
incl item 061, 120 ink),item 061, 120

048 1IE Spur gear Tandhjul

073
06'

085
/ 2/E

2/E

4/E
Control drive bearing Lejehasning

Bolt

Axial bearing ring

Bolt

Lejering

097 21E Axle Aksel

107 1 l
Z/E )washer Skive

Motrik

120
l1 ,/E ISpur gear Tandhjul

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsi side 500.50.
= Only available a s part o f a spare parts kit. = Kun tilgaengelig sorn en del af et resewedelssEt.
QtylE = QtylEngine Qty/E = Qty/Motor

01.43 - ESO
 ZJMD - B&W

Plate
Page 1 (2) Camshaft (Valve Camshaft) 50705-03H

\\m \
:em No for 051 075 099

8 cyl.

134 158 171 195

97.48 - ESO - ---

--
-- - ----
CEFERATMKj
-v--- SETS
 Plate
50705-03H Camshaft (Valve Camshaft) Page 2 (2)

1 1
'i? Qty Designation Benavnelse

I 1/C
1
Carnshaftpart Styreakselsektion 2iE 11 Bearing dirk, Lejesale.

1
Oi4 piece 9 cyl. engine 9 cyl. motor

II
1
026 2/E Bearing disk, Lejesole, 2/E Bearing disk, Lejesale,
5 cyl, engine 5 cyl. motor 9 cyl. engine 9 cyl. motor
I
018 ilE
I
Bearing disk,
5 cyl. engine
Lejesale, 230 ( 1/E ( Axial bearing disk Aksial lejesa!e
5 cyl. motor l l

Bearing disk, Lejesele, 242 1 1IE

11 Bearing segment
end
Leiesole. ende

6 cyl. engine

Bearing disk,
6 cyl moto~

Lejesele,
l/E 1 Spurwheel Cyli~drisktandhjul

6 cyl, engine 6 cyl. motor Screw Skrue

5 cyl. engine 5 cyl, motor
Bearing disk Lejesale 6 cyl. engine 6 cyl, motor
6 cy l. engine 6 cyl. notor 7 cyl. engine 7 cyl motor
8 cyl. engine 8 cyl. motor 8 cyl. engine 8 cyl, motor
9 cyl. engine 9 cyl. motor
Bearing disk Lejeseie
6 cyl. engine 6 cyl. motor Washer Skive
9 cyl. engine 9 cyl motor 5 cyl, engine 5 cyl. motor
6 cyl. engine 6 cyl. motor
Bearing disk, Lejesale, 7 cyl, engine 7 cyl. motor
6 cyl. engine 6 cyl. motor 8 cyl. engine 8 cyl. motor
9 cyl, engine 9 cyl. motor
Bearing disk, Lejesale,
7 cyl. engine 7 cyl. motor Cylindrical pin Cylindrisk stifi
5 cyl. engine 5 cyl. motor
Bearing disk, Lejesnle, 6 cyl, engine 6 cyl. motor
7 cyl, engine 7 cyl. motor 7 cyl. engine 7 cyl. motor
8 cyl, engine 8 cyl. motor
Bearing disk, Lejesale, 9 cyl. engine 9 cyl. motor
7 cyl. engine 7 cyl. motor

Bearing disk,
8 cyl. engine

Bearing disk,
Lejesale,
8 cyl. motor

Lejessle,
313. 1 liE
3/E
l1 Bearing plate, com-
plete incl. item 313

Expander plug
Lejeplade, kornplet
ink1 item 313

Ekspansionsprop

8 cyl. engine 8 cyl. motor 325 ( l/E Intermediate ring,

only for 9Ll6124
Mellenring,
kun for 9L16124
Bearing disk, Lejesale, l

jl 1l
8 cyl. engine 8 cyl. motor Damper, Dsmper,
only for 9L16124 kun for 9L16124
Bearing disk, Lejesale. 337 liE
8 cyl, engine 8 cyl. motor 349 71E Screw. Skrue,
only for 5.8Ll.5124 kun for 5-8L16124
Bearing disk, Lejesele, 1
8 cyl. engine 8 cyl. motor Camshaft bearing Styreakselleje
5 cyl. engine 5 cyl. motor
Bearing disk, Lejesele, 6 cyl. engine 6 cyl. motor
8 cyl. engine 8 cyl. motor 7 cyl. engine 7 cyl. motor
8 cyl. engine 8 cyl. motor
Bearing disk, Lejesele. 9 cyl. engine 9 cyl. motor
9 cyl. engine 9 cyl. motor
7/E ( Screw.
only for 9L16124
Skrue,
kun for 9L16124

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsi side 500.50
= Only available as part of a spare parts kit. = Kun tilgaengelig som en del af et reservede1ss;et.
- QtylE = QtylEngine QtylE = QtylMotor
Qty.lC = QtyJCylinder Qty.lC = Qty.lCylinder

97.48 - ESO
 ZJMD - B&W

Plate
Page I(2) Camshaft (Injection Camshaft) 50705-04H

M 6 cyl.

bearing disks
7 cyl.
\ -

8 cyl.

9 cyl.

565 577 433 553

97.48 - ESD 0406 - - -- -

--h

~-TE?E?s
 ZJMD - B&W

50705-04H Camshaft (Injection Camshaft) Plate

Page 2 (2)

Item
NO Designation Benavnelse Iiom l 1
Qty Designation Benavnelse

1 1
Qty
i
Screw Skrue 469 2iE Bearing disk. Lejesole,
5 cyl. engine 5 cyl. motor 7 cyl, engine 7 cyl. motor
6 cyl. engine 6 cyl. motor
7 cyl. engine
8 cyl. engine
9 cyl. engine
7 cyl. motor
8 cyl. motor
9 cyl. motor I
2iE
Bearing disk,
7 cyl. engine
Lejesole,
7 cyl. moto~

l
Lejesole,

1501E
1 Washer
5 cyl. engine
Skive
5 cyl. motor liE
Bearing disk:
8 cyl. engine 8 cyl. motor

l
I i
180lE 6 cyl. engine 6 cyl. motor Bearing disk, Lejesole,
210/E 7 cyl, engine 7 cyl. motor 8 cyl. engine 8 cyl. rnotol
2401E 8 cyl. engine 8 cyl motor 494 liE
)
27OIE

i Cylindrical pin
9 c y l engine 9 cyl. motor

Cylindrisk stift i I
liE
Bearing disk,
8 cyl. engine
Lejesole,
8 cyl. motor

lOlE i 5 cyl. engine

12/E j 6 cyl. engine
14/E i 7 cyl. engine
5 cyl. motor
6 cyl. motor
7 cyl. motor IiE l Bearing disk,
8 cyl. engine
Lejesole,
8 cyl. motor

/
16lE 1 8 cyl. engine
18/E
i
1
9 cyl. engine
8 cyl. motor
9 cyl. motor
528 l i
liE
Bearing disk,
8 cyl. engine
Lejesole,
8 cyl. motor

313' 3/E

liE
Expander plug

I1 Damper,
Ekspansionsprop

D~mper, l Bearing disk,

8 cyl. engine
Lejesole,
8 cyl. motor

362 ( IIC /
only for 9L16124

Camshaft part
kun for 9L16124

Styreakselsektion l
21E
Bearing disk,
9 cyl. engine
Lejesole,
9 cyl. motor

l
1 2/E
l
(
piece

Bearing disk, Lejesale, 565 i I 2E

i
Bearing disk,
9 cyl. engine
Lejesole,
9 cyl. motor

374
l
/
5cy1. engine

Bearing disk,
5 c y ~motor
.

Lejesale, 577 I I 21E

Bearing disk,
9 cyl. engine
Lejesale.
9 cyl, motor

5 cyl. engine 5 cyl. motor 589 ( 11E

1
( Axial bearing disk Aksial lejesole

/l l Bearing disk, Lejesale, 590 "lE ngir;;: segment Lejesale, ende

6 cyl. engine 6 cyl, motor
398 IiE
1
408 1/E Bearing disk,
1
6 cyl. engine
Lejesale,
6 cyl. motor
600 l 1 Spur wheel,
5-8 cyl. engine
Cylindrisk tandhjul,
5-8 cyl. motor

1/E
1E
Bearing disk
6 cyl. engine
8 cyl. engine
Lejesale
6 cyl. motor
8 cyl. motor l
liE
Spur wheel,
9 cyl. engine
Cylindrisk tandhjul,
9 cyl. motor

/I /i
Bearing plate, com- Lejeplade, komplet
433 Bearing disk Lejesale plete incl. item 313 inkl. item 313
6 cyl. motor
9 cyl. engine 9 cyl. motor 636 IIE Ring Ring

Bearing disk, Lejesale, Camshaft bearing Styreakselleje

6 cyl. engine 6 cyl. motor 5 cyl. engine 5 cyl. motor
6 cyl. engine 6 cyl. motor
457 2/E Bearing disk, Lejesale, 7 cyl. engine 7 cyl. motor
7 cyl. engine 7 cyl. motor 8 cyl. engine 8 cyl. motor
9 cyl. engine 9 cyl. motor

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se o g s i side 500.50
* = Only available as part o f a spare parts kit. = Kun tilgzngelig som en del af et reservedelssst.
QtylE = QtyIEngine Qty/E = QtylMotor
Qty.lC = QtyJCylinder Qty.lC = Qty./Cylinder

---
--
-----
!E
m
= --
---
CBUERATINC SETS
97.48 - ESO
 IndexPage
Operating Gear for Inlet Valves,
Exhaust Valves and Fuel Injection
l
l Pumps
I
'
:operating gear for valve and fuel injection pumps ~ S O Z . O I ( 5 2 5 ) I

jInspectron o f v a l v e roller gurcle I~Q~-GL.QG C03H) I

;Control o f valve clearance Isos-cir,lo ( 0 9 ~ ~ )

l
iSafe valve a d j u s t m e n t

' ~ o l l eguide
r a n d p u s h rods j3 5 ~ 8 ~ 1 - 0 2 . 6 - ;
 Description 508.01
Page 1 (1) Operating Gear for Valve and Fuel Injection Pumps Edition02H

Roller Guides The valve actuating gear is pressure-feed lubricated

from the centralized lubricating system, through the
The fuel injection pumps and rockerarmsfor inlet and waterchamber part and from there into the rocker arm
exhaust valves are operated by the cams on the shaft to the rocker bearing.
camshafts through roller guides. The rollerguidesfor
inlet and exhaust valves are located in bores in the
water jacket for each cylinder.

The roller runs ona bush fitted on a pin that is pressed

into the roller guide and secured by means of a lock
screw.

Operating Gear for Fuel I n j e c t i o n Pumps

The injection pumps which are mounted directly on

the frame are activated via thrust pieces from the
roller guide. The rollerguide is incorporated in the fuel
pump as one unit.

The roller is pressed down on to the cam by a spring:

which is fixed between the roller guide and the foot
plate ofthe fuel injection pump, see also section514.

Valve Actuating Gear

The rocker arms are actuated through rollers, roller

guides and push rods. The rollerguidesfor inlet and
exhaust valves are mounted in the waterjacket part.
For dismantling, a side cover on the push rod chamber
is provided.

Each rocker a n activates two spindles through a

valve bridge with thrust screws and adjusting screws
for valve clearance. Fig l Valve operating gear

98.38 - ESO
 ZJMD - E&W

Working Card 508-01.OO

Page 1 (2) Inspection of Valve Roller Guide Edition 03H

Safety precautions Special tools

Stopped engine Plate no ltem no Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel o l
Stopped lub oil crrcul.
C Press Block~ng- Reset

Description Hand tools

Dismounting, inspection andlor overhaul, and

mounting of valve roller guides.

Starting position

Cylinder unit has been removed from engine and

dismantled.

Related procedure

Control and adjusting of valve

clearance, 508-01 .l0

Manpower Replacement and wearing parts

Working time : 2 hours Plate no Item no Qtyl
N
Capacity 1 man
F

V
e
LD
D
M
-.
1 Data
S4 Data for pressure and tolerance (Page 500.35)
.S
a
m
Data for torque moment (Page 500.40)
Q Declaration of weight (Page 500.45)
['MAN!'
( =&W ZJMD - B&W

508-01 .oo Inspec,tion of Valve Roller Guides

Working Card
Page 2 (2)
Edition 03H

I) Turn the waterjacket upside down so the roller

guides can slip out at the water jacket.
I Roll
lns~ect

2) Examine the surface of the roller and the

tappet housing for marks and secures, if any
they must be polished away.

Blow clean the lubricating ducts in the tappet water

3)
housing and the roller with air.

4) Excamine the push rod, pin and ball cup for

damage and replace if necessary.

Replacement of Roller a n d Shaft Pin ~ i Iginspection o f r o ~ egujde

r and roller

5) Remove the lock screw.

6) Push out the axle.

The roller and axle can now be replaced.

7) Mount the lock screw with loctite 275.

M o u n t i n g of R o l l e r G u i d e

8) Mount the tappet housing with roller in the

water jacket.

Note: Be sure that the recess in the tappet housing

is resting on the cylindrical pin in the roller guide
housing. This ensure thatthe tappet housing can not
turn in the roller guide housing.

98.47 - ESO
 ZJMD -
Working Card
Control of Valve Clearance
508-01.l
0
Page I(2) Edition 09H

'
l

Safety precautions Special tools

E Stopped engine Plate no ltem no Note
E Shut-off starting alr
Shut-off cool~ngwater
Shut-off fuel or1
Stopped lub oil c~rcul
E Press Blockrng - Reset

Description Hand tols

Control andlor adjusting of valve clearance.

Starting position
Cover for valve cam is removed.
Cover for rocker arm is removed.

Related procedure

Safe valve adjustment 508-01.10 (10H)

Replacement and wearing parts

Manpower
Plate no Item no QV\
Working time : 114 hour
Capacity 1 man

Data See also plate 50502.

Data for pressure and tolerance (Page 500.35)

Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

03.43 - ESO 0406

---
-- --------
--
=E.-! . -g
--+
=

GUUERATNC SETS
-=
 508-01.l
0 Work~ngCard
E d h o n 09H
Control of Valve Clearance Page 2 (2)

1) Turn the engine so that the roller, rests on the 2) Lift rocker arm in order to open the valves.
circular part of the cam, i.e. the inlet valves and Control that the valves start to open at the
the exhaust valves are closed. same time.

If the valves do not open at the same time,

make valve adjustment according to working
I card 508-01.l O(1 OH).
l
3) Verify clearance between valve bridge and
rocker arm, pleass see page 500.35for clear-
ance data.

If the valve clearance have to be adjusted,

please see page 508-01.10 (10H)

- Fig 1 Control of valve clearance

- --- -
-
--
-
A
p
---
- -----
--
03.31 - ESO
- p - - - -

Zk~K~iijcYiis 0406
 r
Working Card
Safe Valve Adjustment 508-01.l 0
Page 1 (3)
Edition 10H

Safety precautions: Special tools:

g Stopped engine Plate no ltem no Note

E Shut-off starting air
0 Shut-off cooling water
Shut-off fuel oil
Stopped lub. oil circul.
Press Blocking - reset

/ Description:
I Hand
Verification and/or adjustemenr of inlet and Screew driver
exhaust valves clearance. Torque wrench
Marking ink

Starting position:

Cover for valve camshaft is removed

Cover for rocker arms is removed.
Rocker arms are removed.

Manpower: Replacement and wearing parts:

Working time : ?h hours Plate no Item no Qtyl

Capacity 1 man
See also plate 50502

Data for pressure and tolerance (Page 500.35)

Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

03.43 - ESO
 508-01.l0 Safe Valve Adjustment Working Card
Edition 1 OH Page 2 (3)

1) Before adjustment the rocker arms must be /

removed.

l 1
F I ~ 1.. Cylinder wrthout valve bndge.
Fig.3. The valve bridge in the vice.

2) Loosen the adjusting nut and turn it back one

turn.
3) Press the valve bridge to the valve spindle on
the non-adjustable end and turn the adjusting
screw until you feel contact. Tighten the nut.
5) Apply marking ink on the end of both valve
spindles. Placethe valve bridges on the valve
spindles and press gentle.

l l
4) Place the valve bridge in a vice and apply
correcttorqueon the nut with a torquewrench. Fig. 4. Marking Of

---
E "==-
---
-----
=A-
-p-
- - - m - -

GENERATING SETS 0406 03.43 - ESO

 Working Card 508-01 .l0
Page 3 (3) Safe Valve Adjustment Edition l OH

6) If the valve bridge is correctly adjusted there 9) Install the rocker arms and adjust the clear-
will be inkon both contact surfaces and the ink ance to specified value.
will be clearly touched on both valve spindles.

If the valve bridge do not clearly touch both

valve spindles then clean the marking ink
return to item 3.

Fig. 7. Adjustment of rocker arms.

1 L
Fig.5. Control of adjustment of va!ve bridge
10)
7) Mark the valve bridge adjusting screw and
locking nut clearly to indicate it has been
correctly adjusted and tightened. Mark inlet
and exhaust differently to insure they are not
interchanged.
Tighten the nut with torque wrench to correct
torque. Check the valve clearance once more
after the nut is tightend with correct torque.
The rocker arm adjusting screw and nut to be
marked clearly to indicate it is correct ad-
justed.

l I

Fig.8. 7ightening and marking of rocker arms.

Fig.6. Marking after adjustment and tightening.

N
7
The valves are now correct adjusted and securely
m 8) Turn the engine so that the rollers rest on the
9
v to insure safe operation.
circular part of the cam.
0
LD
N
v)

F
8 Remark
Item 1-6 can be performed, without the cylinder
cover mounted on the engine.

03.43 - ESO --- ---

--
-

- ---
==----
= ==IW
p

---m-
- - W

GENERATING SETS
 Working Card
Page 3 (3) Safe Valve Adjustment
pKiq Edition 1OH

6) If the valve bridge is correctly adjusted there 9) Install the rocker arms and adjust the clear-
will be inkon both contact surfacesandthe ink ance to specified value.
will be clearly touched on both valve spindles.

If the valve bridge do not clearly touch both 1

valve spindles then clean the marking ink
return to item 3. I

1 I Fig. 7. Adjustme,; of rocker arms.

Fg.5. Controi of aclj~st~nent

of valve bridge. Tighten the nut with torque wrench to correct
10)
torque. Check the valve clearance once more
7) Mark the valve bridge adjusting screw and after the nut is tightend with correct torque.
locking nut clearly to indicate it has been The rocker arm adjusting screw and nut to be
correctly adjusted and tightened. Mark inlet marked clearly to indicate it is correct ad-
and exhaust differently to insure they are not justed.
interchanged.

l l

Fig.8. Tighteningand marking of rocker arms.

Fig.6. Marking after adjustment and tightening.

-
N
W 8) Turn the engine so that the rollers rest on the
The valves are now correct adjusted and securely
9
Tr fastened to insure safe operation.
a circular part of the cam.
a
10
N
10
T
n
0 Remark

Item 1-6 can be performed, without the cylinder

cover mounted on the engine.

03.43- ESO - ----- ----

--
-- -S
C 'h==-=
---
- - - - m -

GENERATING SETS
 ZJMD - /&h
Plate
Page I (2) Roller Guide and P u s h Rods 50801 -02H

L,.?.:-
. I..
, ,-.:_ -
,.
I

7:j;-:;.
f+;zz;;:.!, .. <-S....-. !.-.>,, ':>-::<g;
..'.;r.:~-.'.:
, -,--.
.-. / -: ,, ,
, > ~ ~ L.,

Valve Spindles
and Valve Gear,
see plate 50502

97.43 - ESO 0406 --- ----

m
---
€ WE====
CVVERATWC SETS
 ZJMD - B&W

50801-02H Roller Guide and Push Rods Plate

Page 2 ( 2 )

I Qty Designation Benawnelse

41C Thrust piece Trykstykke

2JC Push rod St~dstang

2JC Bolt Bolt

2JC Roller Rulle

2lC Shaft Aksel

2JC Housing for roller Hus for rullestyr

guide

2JC Screw Skrue

When ordering spare parts, see also page 500.50.

Ved bestilling af reservedele, se ogsi side 500.50
t = Only available as part of a spare parts kit. = Kun tilgzngelig som en del af et reservedelsszt.
QtyIC = QtylCylinder. QtyIC = QtylCylinder.
--

--
-- --
- ---
S
=
==
-
=
-

~XTKCYE~S 0406 97.43- ESO

 ZJMD - B&W

I 1 Control and Safety Systems, Automatics 1 509

and Iiistruments 1
I I
/Control and safety systems (32)
js~9.0~
--
i ~ a m b d acontroller ,5Q9.16(07H)
j ~ o m m u n i c a t ~ ofrom
n the GenSet 509.55 (87)

/Functonal test and adjustment of safety, alarm and

a d d -O;sO:i (OZHl
lmonitor~nqequipment
I
fFunction test of shutdown ,sE-Di.G5 (Q?)
Adjustment and test of analogous pressure
1sas-os.03(c3)
itransm~tter
[Adjustment and test of analogous temperature
;5a5-5sZo4( 0 4 H j
;transmitter
I 1
l
I ~ o u n t l n gand adjustment o f pick-ups on engine i509-0e.CI(! (C1Hj I
S

i
j ~ d j u s t m e n to f lambda controller 1509-10.30 ( 0 5 H ) :

!Governor and governor drive

l -
50901-03M
I

l ~ e g u l a t i n gdevice i5QS02-Ci4H
2

I~nstruments jS0909-03H
l
j ~ e v e lswitch in or1 sump (LAL/LAH 28) 15e11928-02H
I
/Fuel oil leakage alarm (LAH 42) 150925-02s
7
j ~ e r m l n a lbox 150935-02H

/ ~ i g i t aspeed
l control, setpoint programmer /50945-OIH
I
IAlarm panel 150946-01H
-. 1 -

/I o _u _t p u t module 150947-038
I

~ A P Mmotor control '50948-01H

I -W-

/valve control box 150949-01H

 Description
Safety, Control and Monitoring System 509.01
Page I(6) Edition 11

General

General Description The engine is equipped with the following main

safety, control and monitoring components:
Monitoring and instrumentation on the engine repre-
sents a tailor-made system. The system is designed Safety system
to fulfil the following requirements: Governor
Monitoring modules
Continuous analogue monitoring - base module
Independent safety system - operation box (OB)
Easy installation - monitoring of temperatures/pressures
Simple operation panel (MTP)
Instrumentation complete - monitoring of exhaust gas temperature
No maintenance panel (MEG)
Prepared for CoCoS - monitoring of bearing temperature panel
Redundant safety system (MBT), option
- bearing temperature display (BTD), option
- oil mist detector, option
In orderto fulfil all classification society requirements Instrumentation (sensors, wiring, junction
the engine is equipped with monitoring sensors for boxes)
all medias as standard. If just one classification Manometers and thermometers
society require one specific measuring point it is Output module, option
standard on the engine. Also a built-on safety system Alarm panel, option
is standard.

Operating Monitoring
; MBD-H
Module
\ of Bearing
Temperature
/ Supply (option for
Engine Control
Room Monitoring -
L27138)

\
Display for
Bearing
Temperature
N
(option for L27138)
7

m
9
*m
2
LD
LD
N
I
5
9
m
N
0
m
0
I I

Fig I Monitoring and safety system.

03.33 - ES1 0406

- - - ---
-
e??zss FEE--
---m-
GENERATINGSETS
--
 ZJMD
509.01 Safety, Control and Monitoring System
Edition 11
General
Safety System
The safety system is an independent system for
monitoring and controlling the GenSet's shutdown
functions.
The safety system is based on a programme logic
controller (PLC) which automatically controls the
automatically stop (shutdown) in case of:
Shutdown
l)Overspeed
2) Low lube oil pressure
3) High HT water temp.
4) Emergency stop
5) High bearing temp. (option)
6 ) Oil mist stop (option)
Set points and special conditions can be found in the
"Operation Data & Set Points, B 19 00 0"
Connection to and from the power management
system is hard wire connection.
Indication of each shutdown can be found on the
operation box and directly on the safety system
module inside the terminal box.
Governor
The engine speed is controlled by a hydraulic gover-
nor or electronic controller with hydraulic actuator.
Information about the design, function and operation
of the governor is found in the special governor
instruction book.
The governor is mounted on the flywheel end of the
engine and is driven from the camshaft via a cylindri-
cal gear wheel and a set of bevel gears.
Regulating S h a f t
The governor's movements are transmitted through
a spring-loaded pull rod to the fuel injection pump
regulating shaft which is fitted along the engine.
- B&W
Description
Page 2 (6)
The spring-loaded pull rod permits the governor to
give full deflection even if the stop cylinder of the
manoeuvering system keeps the fuel injection pump
at "no fuel" position.
Each fuel injection pump is connected to the com-
mon, longitudinal regulating shaft by means of a
spring-loaded arm.
Should a fuel plunger seize in its barrel, thus blocking
the regulating guide, governing of the remaining fuel
injection pumps ma\, continue unafiected owing to
the spring-loaded linkage between the blocked pump
and the regulating shaft.
M o n i t o r i n g System
All media systems are equipped with temperature
sensors and pressure sensors for local and remote
reading.
The sensors for monitoring and alarming are con-
nected to the base module.
Base M o d u l e
The base module is the centre of the monitoring
system.
The base module, the OB-module, the MTP-module
and the MEG-module are designed by MAN B&W
Diesel AIS, Holeby specifically for this engine type.
Apart from the electrical main connection t o the
alternator the ship yard only has to perform the
following electrical connection:
- 24 VDC supply to the safety system.
- Cable connection tolfrom power manage- N
m
ment system. 9
- 24 VDC supply to the base module. .
P
m
m
0
- Modbus communication or interlink to output m
N
module.
I
8
m
N
The vessel's alarm and monitoring system in the 2
main switch board can be connected to the base
module by means ofa 3-wire MODBUS communica-
tion link. For further information, please see the
description "Communication from the GenSet".
 Description
Safety, Control and Monitoring System 509.0j
Page 3 (6) Edition 11

General

In situations where the vessel's system cannot oper- a Shutdowns indication:

ate a MODBUS communication unit, MBD-H offers - overspeed
an output module (OM) to be installed in the vessel's - low lub. oil pressure
control room. - high fresh water temp.
- emergency stop l oil mist
By means ofthe OM it is possible toconnect all digital
and analogue signals to the vessel's monitoring Please note that the local stop push button must be
system in a conventional manner. activated at least 3 sec. before the engine will stop.

Communication between the base module (BM) and

the output module (OM) takes place via a 3-wire
interlink bus (RS485).

In the base module all the alarms are generated and

delay and cut-off at standstill is done. Set points and
special conditions can be found in "Operation Data
& Set Points, B 19 00 0".

The set points for above redundant safety stop are

adjusted to a higherflower point as the safety sys-
tem. This will secure that the safety system will
normally stop the engine in a critical situation. Only
in case that the safety system is out of order the
redundant safety stop will be needed.

Operating Box Module (06)

This module includes the following possibilities:

a Operation of: Fig 2 Operation box module (06).

- engine start
- engine stop
- remote mode The manual start button must be activated until
- local mode ignition; takes place. Ifthe engine have been without
- blockingfreset mode prelubrication in more than 20 minutes the engine
- lamp test can not be electrical started.
- arrow up- shift upwards through measure-
ments for display The push buttons REMOTE - LOCAL - BLOCKING
- arrow down - shift downwards through is only related to the start function. In case of
-
N
measurements for display BLOCKINGthe engine can not be started from local
m
0

i
m
or from remote (switchboard).
3
LD
Indication of:
N
m - Engine rpm The stop function is not depended of the REMOTE
zc1 - TC rpm - LOCAL - BLOCKING position.
0
m - Starting air pressure
N
0
m - Display for digital read out On the local operating box module the pressure,
0
- lndication of software version temperature and rpm are illustrated by means of a
display: an LED indicates whether it is the working
hours, alternator, pressure, temperature orrpm which
is measured.
 ZJMD- B&W

509.07 Description
Edition 11
Safety, Control and Monitoring System Page 4 (6)

General

The display of the operation box module is used to

read each individual measurement chosen by using
"arrow up" or "arrow down" incl. MTP and MEG
measurements. All rpm, pressures and tempera-
tures are indicated in fullvalues. Thevalue displayed
is indicated by flashing of the last segment of the
bargraph on the OB, MTP or MEG module.

If the lamp test button is activated for more than 3

sec. the software version will be displayed.

Normal/
neutral

One segment
below normal
J
l Nine segments
below normal

One segment
above normal
Fig 4 Monifor femp./press. (MJP)

Nine segments Monitoring of Exhaust Gas Temperature

aSove normal
Fig 3 Monitoring of temperatureipressure module (MTP).
Panel (MEG)
The temperature shown on the MEG module is
indicated with segments illuminated from the left to
the right. The number' of segments illuminated de-
pends on the actual temperature ofthe exhaust gas.

Monitoring of Temp.iPressure Panel (MTP)

All temperatures and pressures shown on the MTP

module's bargraph are indicated with illuminated Min. temp.
segments. When the temperatures and pressures reading
are within the stated limits, two segments are illumi-
nated in the middle forming a straight line. This Max. temp.
means that it is easy to check the engines'systems, reading
even at distance.
m
Fig 5 Monitoring of exhaust gas temperature module (MEG). 9
If there is a deviation, the bargraph in question will
2!
start to illuminate the segments upwards or down-
wards, depending on rising or falling measurements,
see fig 4. For emergency operation in case of totally black-out
on the 24 V DC supply the engine is equipped with
2
2
m
It must be mentioned that the latter does not apply to manometers for: 0

the charge air temperature and charge air pressure,

because they will vary with the engine load. - Lub. oil pressure
- Cooling water pressure
- Fuel oil pressure
 ZJMD - 6&W

Description
Safety, Control and Monitoring System 509.01
Page 5 (6)
Edition 11

General

and thermometers for: Monitoring o f Bearing Temperature, M B T

(option)
- Cooling water temp.
- Fuel oil temp. The temperature shown on the MBT module is
indicated with segments illuminated from the left to
the right. The number of segments illuminated de-
pends on the actual temperature of the bearing
temperature

Display for Bearing Temperature Display,

BTD (option)

On the bearingtemperature display the excact meas-

uring value for each individual bearing temperautre
can be read. Furthermore an indication of high
bearing temperature alarm and very high bearing
temperature shutdown are indicated.

Output Module (option)

For alarm systems which cannot be communicated

I I
Fig 6 Monitor exh. gas temperature (MEGJ.
through the MODBUS protocol, an output module
has been designed. This module includes conven-
tional output signals (4-20 mA) for all analogue
measuring values, signals for limit values, and infor-
mation signals from the safety system.

l I

Fig 7 Monitoring of bearing temperature (MBTJ,option. Fig 8 Display for bearing temperature (BTDJ,option.

=
==_= m---

E-%"-
CENERPTING SETS
509.01 Safety, Control and Monitoring System Description
Edition 11 Page 6 (6)

General

The output module will be delivered in a separate
box (1P56) with the dimensions (HILIW): 380x 380x
155 mm.
Alarm Panel (option)
An alarm panel with 24 alarm points can be con-
nected to the system. The alarm panel can be
installed on the engine or in the engine control room,
see fig 7. The dimensions for the panel are (HIUW):
144 X 96 X 35 mm.
It is important that all alarms leads to prompt inves-
tigation and remedy ofthe error. No alarm is insignifi-
cant. It is therefore important that all engine crew
members are familiarwith and well trained in the use
and importance of the alarm system.The most seri-
ous alarms are equipped with slowdown andlor
shutdown functions.
Instrumentation
Pressure measurements are generated from the
pressure transmitters.

The exhaust gas temperatures are generated b y

NiCrINi thermo sensors.

Temperatures are generated by PT100 sensors.

The above transmitters and sensors are specially

designed for installation on diesel engines.

The pressure sensors are placed centrally at the

front of the engine, facilitating easy access for main-
tenance and overhauls, and minimizing wire con-
nections.

The temperature sensors are placed at the measur-

ing point.

Data
l I
Power supply : 24 VDC +20%,
Fig 9 Alarm panel.
max ripple 10%
Power consumption : 2 amp
Ambient temp. : -20% to 70°C
External
communication links : MODBUS ASCll l RTU or
interlink (RS422 / RS485)
 ZJMD - =&W

Description
Page I (1) Lambda C0n3tr011er Edition O ~ H

Purpose If the system isactivated more than 10 seconds, the

The purpose with the lambda controller is to prevent
injectionof more fuel in the combustion chamberthan
can be burned during a momentary load increase.
This is carried out by controlling the relation between
the fuel index and the charge air pressure.
The Lambda controller is also used as stop cy!inder.
solenoid valve will be shut off and there will be a
remote signal for "jet system failure".
The jet system is blocked when engine speed is
below 50 rpm.
During the start procedure the jet system is used as
a charge air booster.

Hereby heavy smoke formation is prevented during

Advantages start procedure.

The lambda controller has the following advantages:

- Reduction of visible smoke in case of sudden

momentary load increases.

- Improved load ability. 1. Regulabng arm

2. Switch (pi&-up)

- Less fouling ofthe engine's exhaust gas ways.

3. P i o n
4. Jet system
solenoid vatve
- Limitation of fuel oil index during starting 5. Lambda cyfnckr
6. ShkbJowl
procedure. sole no.^ vabe

Principles for Functioning

Figure 1illustrates the controlletsoperation mode. In

case of asudden load increase, the regulating device
will increase the index on the injection pumps and
hereby the regulator arm ( l )is turned, the switch (2)
will touch the piston arm (3) and be pushed down-
wards, whereby the electrical signal is sentto base
module (BM).

Thus the solenoid valve (4) controlled by the BM is

activated, the turbocharger accelerates and increases
the charge air pressure, thereby pressing the piston
(3) backwards in the lambda cylinder (5). When the
lambda ratio is satisfactory, thesolenoid valvewill be
m
9
W
de-activated.
m
6
m
2 Above system is also called jet system.
50
4
m
N At a 50% load change the system will be activatedfor Fig l Principle drawing of lambda controller
0
m about 3-8 seconds.

02.41 - ESO
 ZJMD - B&W

Description
Communication from the GenSet 509.55
Page I(9)
Edition 07

General

System Layout All signals can be wired up from the OM-

Fig 1 shows the system layout. 'The modules BM,
OB, MTP, MEG and safety system are all placed on
the engine. More detailed information on each mod-
ule and sensors can be read in the description
"Safety, Control and Monitoring System".
module to the ship's alarm & monitoring sys-
tem.
3) A simple alarm panel (AP) with 24 LED chan-
nels can be installed in the control room. This
solution only serves digital alarms.

Ifthe alarm system can communicate with MODBUS

Communication
Communication from the BM-modole to the ship's
alarm L? monitoring system can be done in three
ways:
1) In the BM-module there is a MODBUS ASCll
or RTU interface communication.
2) An output module (OM) can be placed in the
control room switchboard or alarm disk. Com-
munication from the BM-module to the OM-
module is made via the 3 wire module interlink
bus.
In the OM-module ail the signals are converted
into 4-20 mA signals and digital outputs.
ASCll or RTU, there is no need for the OM-module
or AP. All signals can be communicated by the
MODBUS.
In the following please find a description of the
MODBUS protocol and addressing of the signals.
MODBUS Protocol (BM)
The BM has a standard MODBUS ASCll and RTU
interface which may be selected, by means of a DIP
switch on the BM, to be either:
- RS422 5 wire ( B + , Rx-, Tx+,Tx-, GND) or
- RS485 3 wire (B+/Tx+, Rx-/lx-, GND)

DO = D~grtaloutput
1 MODBUS ASCll or RTL D1 = Digital input
Interface (Slave) AI = Analog input
'/" 6 DO R5485 or RS422

-
~ , s s senglne
~ 1
2 DI A 0 = Analog output
A
31 A 0 4-20
; A *30 DO
031101 /

I OM
1 output
BM module

(
1 Aaim
panel
l
1 l 1 ,

Module interiink bus (RS485) l

l l 1 l

Temp. 8
Press.

24V DC*

*must be from separate sources (UPS)

Fig l System overview: "monitoringsystem & safety system"

509.55 Description
Edition 07
Communication from the GenSet Page 2 (9)

General

The communication setup is: 9600 baud, 8 databits, The general ,,message frame format" has the follow-
1 stopbit, no parity. ing outlook:

The BM MODBUS protocol accept one command [:l [SLAVE] [FCT] [DATA] [CHECKSUM] [CR] [LF]
(Function Code 03) for reading analog and digital
input values one at a time, or as a block of up to 32 - [:l 1 char. Begin of frame
inputs. - [SLAVE] 2 char. Modbus slave address
Selected on DIP-switch at BM
MODBUS is defined by the company AEG Modicon print
and the implementated protocol in the BM is de- - [FCT] 2 char. Function code
signed to observe the relevant demands in the latest - [DATA] n X 2 chars data.
protocol description from AEG Modicon: - [CHECKSUM] 2 char checksum (LRC)
- [CRI 1 char CR
,,MODBUS protocol, reference guide document No - [LFl 1 char LF (end of frame)
PI-NIBUS-300, Rev. G"
Notice: The MODBUS address [SLAVE] should be
Since the standard refers to specific types of hard- adjusted on the DIP-switch (SW 1) on the BM.
ware, it should be noted that all MODBUS addresses Allowed addresses are 1..254 (0 and 255 not in use).
in the list "Summary of Alarms" for the plant in Broadcast packages will not be accepted (to be
question, refers directly to the addresses as they ignored), see fig 2.
appear on the line. These addresses should thus not
be offset by one in any direction. The following function codes (FCT) is accepted:

The following chapter describes the commands in - 03H: Read n words at specific address
the MODBUS protocol, which are implementated,
and how they work. In response to the message frame, the slave (BM)
must answer with appropriate data. If this is not
possible, a package with the most important bit in
Protocol Description FCTset to 1 will be returned, followed by an excep-
tion code, where the following is supported:
The ASCll version of the MODBUS protocol is used,
where the B M works as MODBUS slave. As this is a - 01: Illegal function
ASCll protocol, all data bytes will be converted to 2- - 02: Illegal data address
ASCll characters (hex-values). Thus, when below is - 03: Illegal data value
referred to .bytesu or.words", these will fill out 2 o r 4 - 06: BUSY. Message rejected
characters, respectively in the protocol.

SW 1: MODBUS address

Switch no 1 2 3 4 5 6 7 8

Address:
0 OFF OFF OFF OFF OFF OFF OFF OFF Not allowed
1 ON OFF OFF OFF OFF OFF OFF OFF
2 OFF ON OFF OFF OFF OFF OFF OFF

254 OFF ON ON ON ON ON ON ON
255 ON ON ON ON ON ON ON ON Not allowed

Fig 2 Modbus address

 ZJMD - B&W

Description
Page 3 (9)
l Communication from the GenSet 1 509.55
Edition 07 l
General
FCT = 03H: Read n w o r d s The following types of data format have been cho-
sen:
The master transmits an inquiry to the slave (BM) to
read a number (n) of datawords from a given ad- Digital: Consists of 1 word (register):
dress. The slave (BM) replies with the required Iword: [0000H]=OFF
number (n) of datawords. To read a single register [FFFFH]=ON
(n) must be set to 1. To read block type register (n)
must be in the range 1...32. Integer: Consists of 1 word (register):
1 word: 12 bit signed data
Request (master): (second complement):
[@OOOH]=O
[DATA] = [ADR][n] [OFFFH]=100% of range
[ADR]=Word stating the address in HEX. [FOOOH]=-100% of range
[n]=Word stating the number of words
to be read. Notice: 12 bit data format must be used no matter
what dissolution a signal is sampled with. All mea-
Answer (slave-BM): suring values will be scaled to 12 bit signed.

[DATA] = [bb][l . word][2. word] ....[n. word] Example l:

[bb]=Byte, stating number ofsubsequent
bytes. PI 10, range 0-6 bar
[ l . word]=l . dataword The value 2.3 bar will be represented as 38.33% of
[2. word]=2. dataword 6 bar = 0621H
[n. word]=No n. dataword

MODBUS a d d r e s s i n g
In order to be able to read from the different I10 and
data areas, they have to be supplied with an .ad-
dress".
MODBUS Tirneout
To prevent lock up of the protocol, ie. a breakdown
on the connection, a number of timeouts are to be
built in, as specified in the MODBUS protocol speci-
f cation:

In the MODBUS protocol each address refers to a MODBUS specification max. time between charac-
word or,,register". Forthe GenSet there are following ters in a frame: 10 ms
I10 registers:
MODBUS specification max. time between receipt of
- Block (multiple) 110 registers occupying up to frame and answer: 1 second
32 word of registers (see table 3, 4, 5 and 6).
However the implementation of the protocol in the
Block I10 registers hold up to 32 discrete 110's placed GenSet Base Module is able to handle much smaller
at adjacent addresses, so it is possible to request timeouts (response times), which may be required in
8
W
any number of 110's up to 32 in a single MODBUS order to obtain an acceptable worst-case I10 scan
e command, Please refer to table 3,4, 5 and 6 which time:
ln
,N specifies the block 110s registers addresses and how
g the individual 110's are situated within the ,,block". Base Module, max. time between characters in a
W
(U
frame: 5 ms
0
a
J
0

Data F o r m a t Base Module, max. time between receipt of frame

and answer: 100 ms
The MODBUS protocol does not define the data
format, which therefore can be determined freely.
 MAN L;
L saw i ZJMD - B&W
I

509.55 Description
Edition 07
Communication from the GenSet Page 4 (9)

General

In the tables below each signal has a importance
statement with following meaning:
Required by the classification society or MAN B&W.
Recommended by MAN B&W.
"Nice to have".
In the tables below somesignals have a remark with
following meaning:
a) Required by American Bureau of Shipping,
ABS.
b) Required by Bureau Veritas, BV.
c) Required by Jugoslavenski Register & DnV.
d) Required by Registro ltaliano Navale, RIIVA.
e) Required by Nippon Kaiji Kyokai, hIKK & DnV.
f ) Bureau Veritas, Lloyds Register of Shipping
and ABS demand alarm point for lowlhigh
heavy fuel oil temp. Normally this is placed at
yard side as an common alarm for all aux
engines. The signal can also be generated
from iT140.
g) "Common shutdown" consists of following sig-
nals: PSL22, TSH12, SSH81 and ZS82 (as
option TSH29127 for L27138 or LSH92 for L271
38 and L3.2140). Furthermore it consist also of
the redundant shutdowns performed in the
Base Module.
Table 3 (Block scanning)
Signal Nameidescription Address
h) "Safety system failure" consists of following
signals: Power supply failure and internal
watch dog alarm.
i) "Safety sensor cable failure" means cable fail-
ureonone or moreoffollowing sensors: lub. oil
pressostate PSL22, cool. water ther-mostate
TSH12, speed pick-up SE90-2 or emergency
stop switch ZS82 (as option TSH29127for L271
38 or LSH92 for L27138 and L32140)
j) "Local shutdown" only consists of the shut-
downs (PSL22, TSH, SSH81, and ZS82) in the
safety system.
k) For L27138, L21131 and L32140 the signal
ZS82, also includes high oil mist shutdown,
LSH92.
I) Only available for L27138 (standard on 8 and 9
cyl. engine), L32140 and L21131 (option).
m) Required by Det Norske Veritas, DnV.
n) For L16124 engine type TC rpm range is O-
80000.
o) Not accepted by all classification societies.
p) For GenSeis with high voltage alternators.
General) All alarm signals are already performed
with necessary time delay. F.ex. lub. oil level
alarms (LAULAH28) includes 30 sec. alarm
delay. Start air alarm (PALTO) includes 15 sec.
alarm delay. No further delay are needed.
Data format Importance Remark Meas. range

oLAH42 Drain box high level 4002 Digital Required

oPAL25 Prelub. oil low press. 4003 Digital Required
oSx32 Jet system failure 4004 Digital Required
oUX95-2 Safety system failure 4005 Digital Required h)
oSS86 Common shutdown 4006 Digital Required 9)
oTAH98 Altematorwinding temp. high 4007 Digital Required
oPAL10 HT water press. inlet low 4008 Digital Required
oPAL70 Starting air press. low 4009 Digital Required
oPDAH21-22 Diff. press. high, lub. oil filter 400A Digital Required
OPAL 22 Lub. oil press. inlet low 4008 Digital Required
oPAL40 Fuel press. low 400C Digital Required
oTAH 12 HT water temp. high 400D Digital Required
oTAH2 1 Lub. oil temp. inlet high 400E Digital Required
oLAL28 Low oil level base frame 400F Digital Recommended b)
oLAH28 High oil level base frame 4010 Digital Recommended
iZS75 Microswitch, turning gear engaged 401 1 Digital Recommended b)
oSAH8 l Overspeed alarm 4012 Digital Recommended
oTAD6O &h. gas temp. high or low 4013 Digital Recommended m)
oTAH61 TC temp. outlet, high 4014 Digital Recommended
oTAH62 TC temp. inlet, high 4015 Digital Recommended m)

Cont.
 Description 509.55
Page S (9) Communication from the GenSet Edition 07

General

Cont. of table 3
Signal Nameldescription Address Data format Importance Remark

l
HT water temp. outlet lntegeter 12 BII Recommended 0-200" C
Lub, oil temp. inlet lntegeter 12 Bit Recommended 0-200' C
Fuel oil temp. inlet Integeter l 2 Bit Recommended 0-200" C
Alternator winding temp. 1 Integeter 12 Bit Recommended 0-200" C
Alternator winding temp. 2 lntegeter 12 Bit Recommended 0-200" C
Alternator winding temp 3 lntegeter 12 Bit Recommended 0-200" C
HT water press. inlet lntegeter 12 Bi: Recommended 0-6 bar
Lub. oil press inlet engine lntegeter 12 Bi! Recommended 0-10 bar
Fuel oil press. inlet lntegeter 12 BI: Recommended 0-16 bar
Starting air pressure lntegeter 12 B:: iiecomnended 0-40 bar
Safety sensor cable failure Digital Recommended
Start failure Digital Recommended
p -

Table 3 MODBUS block l (multiple i / ~ )register addressing.

Table 4 (Block scannina)

I Signal I Narneldescription 1 Address ( Data format I Importance I Remark I Meas. range (
iPSL22 Lub. oil inlet low pressure, stop 4042 Digital Nice to have
iTSH12 HT water outlet high temp., stop 4043 Digital Nice to have
iZS82 (LSH92) Emergency shutdown (oil mist) 4044 Digital Nice to have
iSSH81 Overspeed stop 4045 Digital Nice to have
oZS96 Local indication 4046 Digital Nice to have
ozs97 Remote indication 4047 Digital Nice to have
OSASS (Spare) 4048 Digital
oSS9OA Engine running 4049 Digital Nice to have
iTE60-1 Exh. gas temp., cylinder 1 404A Integer 12 Bit Nice to have
iTE60-2 Exh. gas temp., cylinder 2 4048 Integer 12 Bit Nice to have 0-803' C
iTE60-3 Exh. gas temp., cylinder 3 404C lnteger 12 Bi: Nice to have 0-803' C
iTE60-4 Exh. gas temp., cylinder 4 404D lnteger 12 Bit Nice to have 0-800' C
iTE60-5 Exh. gas temp., cylinder 5 404E lnteger 12 Bit Nice to have 0-800' C
iTE60-6 Exh. gas temp., cylinder 6 404F lnteger 12 Bit Nice to have o-803° c
iTE60-7 Exh. gas temp., cylinder 7 4050 lnteger 12 Bit Nice to have 0-800" C
iTE60-8 Exh. gas temp., cylinder 8 4051 lnteger 12 Bit Nice to have 0-800' C
iTE60-9 Exh. gas temp., cylinder 9 4052 lnteger 12 Bit Nice to have 0-800' C
iTE61 Exh. gas temp. outlet TC 4053 lnteger 12 Bit Nice to have 0-800' C
iTE62 Exhaust gas temp. inlet TC 4054 lnteger 12 Bit Nice to have 0-800' C
iTlOl LT water temp. inlet 4055 lnteger 12 Bit Nice to have 0-200" C
iT131 Charge air temp. 4056 lnteger 12 Bit Nice to have 0-200' C
iPlOl LT water press. inlet 4057 lnteger 12 Bit Nice to have 0-6 bar
iP121 Lub. oil press. inlet filter 4058 lnteger 12 Bit Nice to have 0-10 bar
iP123 . Lub. oil TC press. 4059 lnteger 12 Bit Nice to have 0-4 bar
iP131 Charge air press. 405A lnteger 12 Bit Nice to have 0-4 bar
oSE9O Engine RPM pickup 4058 lnteger 12 Bit Nice to have 0-1600 rpm
oSE89 TC RPM pickup 405C lnteger 12 Bit Nice to have 0-60000 rpm
oUX95-2-Dly (Spare) 405D Digital
oSX84 Stop failure 405E Digital Nice to have
iSS86-3 Shutdown from safety system 405F Digital Nice to have
oPALOl LT water press. inlet 4060 Digital Nice to have
oPAL23 Lub. oil press. TC, low 4061 Digital Nice to have

Table 4 MODBUS block 2 (multiple i/o) register addressing

 ZJMD - BaCW

509.55 Description
Edition 07
Communication from the GenSet Page 6 (9)

General

Table 5 (Block scanning)

r
I 1 1 Address
$7
I l I

Signal Nameldescription ( Data format Importance Remark Meas. range

oSAH89 High TC rpm 40C2 Digital Nice to have

oTAH62-2 High exh. gas temp. before TC 40C3 Diaital Nice to have
oTAH12-2 High cooling water temp 40C4 Digita! Nice to have
oTAH6O-1 High exh. gas temp cyl. 1 40C5 Digib! Nice to have
oTAH60-2 High exh. gas temp cyl. 2 40C6 Digital N ~ c eto have
oTAH60-3 High exh. gas temp cyl. 3 40C7 Digital Nice to have
oTAH60-4 High exh. gas temp cyl. 4 40C8 Digital kice to have
oTAH60-5 High exh. gas temp cyl. 5 40C9 Digital Nice to have
oTAH60-6 High exh. gas temp cyl. 6 40CA Digital Kice t3 have
oTAH60-7 High exh. gas temp cyl. 7 40CB Digital Nice to have
oTAH60-8 H ~ g hexh. gas temp cyl. 8 40CC Digital Nice t3 have
oTAH60-9 High exh. gas temp cyl. 9 40CD Digital Nice to have
oUX95-1 Monitoring system failure 40CE Digital Recomnende5
oSX86-1 Monitoring sensor failure 40CF Digital Recommended
iLAH92 High oil mist alarm (oil splash) 40D0 Digital Nics to have

Table 5 MODBUS block 3 (mubple r/o) register addressing.

l n d l v ~ d u ascanning
l

Signal Nameldescription Address Data format Importance Remark Meas. range

oZS57 Earth connector & diff. protection 4090 Digi'a' Nice to have P)
 ZJ M D - Baw
Description 509.55
Page 7 (9) Corr~municationfrom the GenSet Edition 07

General

Table 6 (Block scanning)

Signal Nameldescription Address Data format Importance Remark Meas. range

I Following signals are only available as option for engine type L27138.
iT129-1 Main bearing temp. 4005H Integer 12 Bit Nice to have
iT129-2 Main bearing temp. 4004H Integer 12 Bit Nice to have
iT129-3 Main bearing temp. 4003H Integer 12 Bit Nice to have
iT1294 Main bearing temp. 4002H Integer 12 Bit N~ceto have
iT129-5 Main bearing temp. 4006H Integer 12 Bi: Nice to have
iT129-6 Main bearing temp. 4007H Integer 12 ai: K I ; ~to have
iT129-7 Main bearing temp. 4008H Integer 12 Bit N i x to have
iT129-8 Main bearing temp. 4009H Integer 12 Bi: Li;e to have
iT129-9 Main bearing temp. 400AH Integer 12 Bi: Nize rc have
iT129-10 Main bearing temp. 400BC Inteoe; 12 Bi! tilce 10 have
T129-11 Guide bearing temp. 400CH Integer 12 Bit NIE t3 have
oT129-1 Cable break 400DH Digira Nice :c have
oT129-2 Cable break 400EH D,gi:a: U,-. :o have
oT129-3 Cable break 400FH Digi:al NI,: to have
oT1294 Cable break 40: OH Digital Nice :o have
oT129-5 Cable break 4: 1H Dig:ta! S~ceto have
oT129-6 Cable break d052H Digital Nice to have
oT129-7 Cable break 401 3H Digital N~ceto have
oT129-8 Cable break 4014H Digital Nice to have
oTl29-9 Cable break 4015H Digital Nice to have
oT129-10 Cable break 401 6H Digital Nice to have
oT129-11 Cable break 401 7H Digital Nice to have
iT127-1 Alternator bearing temp. 4018H Integer 12 Bit Nice to have
iTI INTERNT. Compensation resistor 401AH Integer 12 Bit Nice to have
oTSH29127 High bearing temp. shutdown 401 BH Digital Nice to have
oTSH29127 High bearing temp. shutdown 401 CH Digital Nice to have
oTSH29127A Common alarm main bearing temp. 401DH Digital Nice to have
oTSH29127B Common alarm main bearing temp. 401EH Digital Nice to have
oUX29127 Common cable failure 401 FH Digital Nice to have

Table 6 MODBUS block 4 (rnutiple i/o) registeraddressing.

Table 7 (Individual scanning of control signals)

Signal Nameldescription Address Data format Importance Remark Meas. range

Running hours C141 32 bit word 2 registers

Start via MODBUS ClCl Digital 0)
Stop via MODBUS C201 Digital 0)
Start counter C241 32 bit word 2 registers

Table 7 MODBUS block 5 (multiple i/o) register addressing

In fig 8 and 9 some examples ofwiring are illustrated.

See also description "Guidelines for cable and
wiring" for further information.
 ZJMD - B&W

509.55 Description
Edition 07
Communication from the GenSet Page 8 (9)

General
Engine type L16124, L21131, L27138 or L32140

I I

Fig 8 MODBUS wmmunication (RS 485 and RS 422).

 k-I" MAN 'i"(,
ZJMD - E&W L B&W i:

Description 509.55
Page 9 (9) Communication from the GenSet Edition 07

General

Engine type L27138 incl. bearing surveillance module

Bearing Surveillance

m~ o d i l (option)
e Base Module

P
L
- -- e = = -- -

Fig 9 MODBUS wmmunicaiion (RS 485).

Comment: Always connect each engine with

separate serial cable to the alarm system. Do not
connect all auxiliary engines on one serial cable
connection.
 ZJMD - B&W

Working Card Functional Test and Adjustment of Safety, 509-01 .OO

Page 1 (2) Alarm and Wionitoring Equipment Edition 0 2 ~

Safety precautions Special tools

Stopped engine Plate no. ltem no. Note

Shut-off starting air l
Shut-off cooling water See "Related procedure"
CI Shut-off fuel oil
Stopped lub. oil circul.
Press Blocking - Reset

Description Hand tools

Function test and adjustment of safety, alarm and See "Related procedure"
monitoring equipment.

Starting position

Related procedure

Functional test of shutdown trip 509-01.05

Analoge pressure transmitter 509-05.03
Analoge temperature transmitter 509-05.04

Manpower Replacement and wearing parts

Working time : hours Plate no. ltem no. Qty. I

Capacity man

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.38- ESO
-= --=
-- =
l&=
-
-
S
,-
S===

CENERATOUCSETS
509-01 .oo Functional Test and Adjustment of Safety, Working Card
Page 2 (2)
Edition 0 2 ~ Alarm and Monitoring Equipment

Maintenance of Monitoring a n d Safety It isrecornmended thatall functionsare tested every

Systems
One of the most important parameters of preventive
work is that the alarm system, as well as the shutdown
and overspeed devices, are functioning 100%.
three months according to the mentioned working
cards.
To check these functions use the working cards
mentioned under related procedure on page 1.

If some of these functions are out of operation, they

must be repaired immediately. If this is not possible
because of the current working situation, the engine
has to be under constant observation until it can be
stopped.

98.38 - ESO
 ZJMD - B&W
-
Working Card 509-01.05
Page 1 (3) FunctionTest of Shutdown Edition 07

General

Safety precautions Special tools

• Stoppedengine Plate no Item no Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Stopped lub. oil circul.
Press button (Blocking - Reset)

Description H a n d tools

Functional test of overspeed trip. Allen key, 4 mm.

Functional test of low lubricating oil pressostate Allen key, 2 mm.
trip. Manometer or test pump.
Functional test of high fresh water thermostat. Large spanner.

Starting p o s i t i o n

Functional test and adjustment of safety

alarm and monitoring equipment 509-01 .OO

Related p r o c e d u r e

Manpower Replacement a n d wearing p a r t s

Working time 1 1 hour Plate no Item no Qtyl

Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

03.39 - ESO 0406

509-01.05 FunctionTest of Shutdown
Working Card
Page 2 (3)
Edition 07

General
It is of the utmost importance that the shutdown
function is working properly. Therefore, the shutdown
function must be tested at regular intervals according
to the plannedmaintenanceprogramme 500.25.

Function Test of Overspeed Shutdown

l) Start the engine locally and keep it at no load,

at nominal rpm -
1000 rpm or 1200 rpm for L16124 engine type
720 rpm or 750 rpm for L27138 engine type
900 rpm or 1000 rpm for L21131 engine type.

2) Take a large spanner and put it on the link

between fuel-rack and governor. Slowly force
the engine rpm overthe setpoint,see Description
500.30 and the overspeed will release.

Warning: Do not raise the speed over 120% of

nominal speed because this could damage the
valves and pistons. Fig l Valve - test valve - pressosfafe

The engine must stop.

3) Reset the overspeed shutdown on the opera- 9) Open the oil pressure valve on the pressure
tion box. block.

10) Resetthe low lubricating oil pressureshutdown

Function Test of Low Lubricating Oil on the operation box.
Pressure Shutdown
Function Test of High Fresh Water
4) Start the engine and keep it at no load. Temperature Shutdown

5) Mount the manometerltest pump on the test
valve outlet, situated right underthe pressostate
PSL 22, fig l.
6) Close oil pressure valve, fig l .
7) Relieve the pressure slowly and checkthat the
switch changes back to the pressurestated as
the shutdown point, see 500.30.
The engine must stop.
Note: If adjustment is needed, turn the screw
clockwise or anticlockwise, see fig 2.
The functional test of the thermostat, is to be carried
out according to the following procedure.
11) Take the sensor out of the pocket.
12) Test the sensor in a water bath, which is
controlled by the temperature or a special
testing device.
13) Start the engine and keep it at no load.
14) Raise the temperature untilthe switch changes
and checkthatit happensatthestatedshutdown
point, see 500.30.

8) Disconnect the manometerltest pump. The engine must stop.

0406 03.39 - ESO

 ZJMD - EBiW

Working Card 509-01.05

Page 3 (3) FunctionTest of Shutdown Edition 07

General

Note: Ifadjustment is needed, removethethermostat

cover. Locking screw pus. 5, fig 3, is loosened, and
therangecan besetwith thespindle, pus. 7,whilethe
scale, pus. 2, is read at the same time.

15) The sensor is mounted again.

16) Resetthe high H.T. water temperatureshutdown

on the operation box.

Fig3 Thermostats

;:*I
Mechanical drffe-eice

Fig 2 Adjustment of pressostate and fhermostate

Alarm System
It is important that all alarms lead to prompt
investigation and remedy of the error.
Noalarm is insignificant. It is thereforeimportantthat
all engine crew members are
familiarwith and well trained in the useand importance
of the alarm system.
The most serious alarms areequipped withslowdown
andlorshutdown functions.

03.39 - ESO 0406

Working Card
Adjustment andTest ofAnalog PressureTransmifter 509-05.03
Page 1 (2) Edition 03H

General

Safety p r e c a u t i o n s Special tools

Stopped engine Plate no Item no Note

17 Shut-off startrng air
Shut-off cooling water
Shut-off fuel oil
U Stopped lub. oil c~rcul.
Press button (Blocking - Reset)

Description Hand tools

Adjustment and test of analog pressuretransmit- Test~ngpump.

ter.

Starting p o s i t i o n

Functional test and adjustment of safety

alarm and monitoring equipment 509-01.OO

Related p r o c e d u r e

Manpower Replacement a n d wearing p a r t s

Working time : % hour Plate no Item no Qtyl

Capacity 1 man

Data

Data for pressure and tolerance (Page500.35)

Data for torque moment (Page 500.40)
Declaration ofweight (Page 500.45)
1 509-05.03
Edition 03H
1 Adjustment and Test ofAnalog Pressure Transmitter
Working Card
Page 2 (2)

General
The pressure transmitter registers the actual pres-
sure and converts the pressure to an electrical
signal.

Adjustment

It is possible to adjust the pressure transmitter by

means of the ,,zeroLscrew and the .span" screw.

l) Adjust the .zero" screw, see fig I , to change I

zero screw
the pressure measurement area. span screw

2) Adjust the .span8'screw, see fig I , to change

the value of the electrical signal acc. to the
I 1
pressure measurementarea. Fig 1 Adjustment of pressure transmiffer

Test I

It is possible to make a functional test of the pressure

transmitter. This is carried out according to the
following procedure:

3) Shut ofsystem pressure with the valve, see fig

2, pos. I .

4) Remove the screw, see fig 2, pos. 2

5) Mount the testing apparatus to the connection

and pump on a pressure within the working area
of the transmitter.

6) Read the pressure at the operating box on the

engine and check it according to the pressure
on the testing apparatus.
Fig 2 Test of pressure transmitter
7) Remove the testing apparatus.

8) Mount the screw, see fig 2, pos. 2.

9) Open the valve, see fig 2, pos. l , for the

system pressure.

02.20 - ESO
 Working Card Adjustment and Test of 509-05.04
Page 1 (2) Analogous Temperature Transmitter Edition 04H

Safety precautions Special tools

Stopped engine Plate no, Item no. Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Stopped lub. oil circul.
Press Blocking - Reset

Description Hand tools

Adjustment and test of analogous temperature Special testing devices

transmitter, (PT 100 sensor).

Starting p o s i t i o n

Related p r o c e d u r e

Functional test and adjustment of safety

alarm and monitoring equipment, 509-01.OO

Manpower Replacement a n d wearing p a r t s

Workingtime : 112 hour Plate no. Item no. Qty.1

Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.43 - ESO
 ZJMD - B&W

509-05.04 Adjustment and Test of Working Card

Edition 04H Analogous Temperature Transmitter Page 2 (2)

The nickel-chrome-nickel sensor, which is used only Test

for measurement of the exhaust gas temperature,
generates a mVsignal depending on the temperature. 2)
The PT 100 sensor consists of a resistance wire
which changes resistance depending on the tempera-
ture. 3)
Functional test of the PT l 0 0 sensor can be
carried out according to the following proce-
dure.
Take the sensor out of the pocket.

Look and design vary depending on the place of 4) Test the thermostate by submerging the sensor
measurement and manufacture. in the water bath, which is controlled by a
special testing apparatus producinga constant
Adjustment temperature.

l) Since the nickel-chrome-nickel sensor and the
PT 100 sensor cannot be adjusted the alarm
limit must be set on the alarm plant.
Set point, see page 500.30.
lfthe alarm plant has an instrument unit, thetempera-
ture can be read on th~s.
Otherwise the test can be carried out by seeing
whetherthe alarm plant givesan alarm when the alarm
limit stated on page 500.30 is exceeded (if the alarm
plant is adjusted).

5) The sensor is mounted again.

Fig 1 PT 100 sensor

98.43 - ESO
 -
Working card
Mounting and Adjustment of Pick-ups on Engine 509-08.00
Page 1 (2) Ed~tion01H

Safety precautions Special tools

l
Stopped engine Plate no Item no Note
Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circulation

1 Description

Mounting and adjustment of pick-ups on engine.

Hand tools

( Starting position
I

( Working hours % Hours

Capacity 1 Man

Data

Data for pressure and tolerance (Page 500.35) Plate no Itern no

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

00.12 - ESO
 509-08.00 Mounting and Adjustment of Pick-ups on Engine Working card
Edition 01 H Page 2 (2)

M o u n t i n g Guidance

Engine rpm pick-up 90-1 and 90-2 and check of plug

for same.

Check to be carried out on stopped engine.

The pick-ups are positioned as indicated on the

enclosure, fig 1.
Tooth on flywheel '

I l

Fig 2 Placing of p~ck-up.

Check o f Plug

Correct plug, see fig 3, rounded off, black head and

grey wire.
Pick-up 90-1 8, 90-2

l I

Fig I Cover on flywheel, seen from exh. side.

Fig 3 correct plug.

M o u n t i n g of Pick-up
Incorrect plug, see fig 4, square, black head and
The pick-up is screwed clockwise until it touches the black wire.
top of a tooth on the gear rim, please see fig 2.

Afterwards, the pick-up is turned one time anti-

clockwise and then the groove of the thread (see fig
2) is put in 3 o'clock or 9 o'clock position seen from
the socket end, .still anti-clockwise.

The pick-up is locked with the counternuts.

Fig 4 Incorrect plug.

--- ---E
m -- -E=-=-

~ - ~ ~ - ~ - G ~ E ~ ? s
0406 00.12 - ESO
 i' MAN !
L B&W t

Working Card
Adjustment of Lambda Controller 509-10.00
Page 1 ( 2 ) Edition 05H

Safety precautions Special tools

G Stoppedengine Plate no Item no Note

B Shut off starting air
Shut off cooling water
[? Shut off fuel oil
Stopped lub. oil circul
E Press Blocking - Reset

Description Hand tools

Adjustment of lambda controller. Adjustablle spanner, 8"

Starting position

Related procedure

Manpower Replacement and wearing parts

Working time 1I 4 hour

Capacity 1 man

Data for pressure and tolerance (Page 500.35)

Data fortorque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.48 - ESO -
---
-
-- P

-v---
- - ---
--
--

CWERKTWC SETS
 ZJMD - B&W

509-10.00 Working Card

Edition 05H
Adjustment of Lambda Controller Page 2 (2)

Adjustment of the Lambda Controller

1 Compressed air from
overspeed device
All adjustments are made when the engine is in
2. Lambda cylinder
standstill position.
3. Charge air pressure

1) Check that the free space between the pick-up

and the band steel on the regulating arm is min 5. Regulating arm

1 mm, see fig 1.

1 Band steel
2 P,C~-LI?
S. Regulahng arm

r ' I l

Fig 3 Removai of pipe for charge air pressure.

2) Set the "load limit" control knob at max.

3) Set the pump index to 13 mm by an adjustable

spanner on fuel rack arm.

4) Fit the adjustment screw (4), fig. 2, until the

Fig l Check of free space.
piston has contactwith the spring without com-
pressing it.

5) Fasten the adjustment screw.

Stop screw 6) Adjustment completed.

Sprlng
Piston rod
Adiusbnent screw
Adjustment of the Stop Screw.

7) Set the pump index to 23 mm (spring on

governor full pressed) by an adjustable spanner
on fuel rack arm.

8) Adjust the stop screw, see fig 2, to 110% load

according to te test bed, plus 1.5 index.
Use the index arm on the fuel injection pump
nearest to the lambda controller as the control
for the index.

9) Adjustment completed.
Fig 2 Fit the adjustment screw.

98.48 - ESO
 Plate
Page 1 ( 2 ) Governor a n d Governor Drive

99.08 - ESO 0406 -- --

-- - ---
* =a=
----!&S
----v-
CUUERATWC SETS
 Plate
50901-03H Governor and Governor Drive , Page 2 (2)

Item Item
no Qty Designation Benavnelse no Qty Designation Benaevnelse

021
I 1IE Synchronnizing Synchroniseringsmotor 319 1 1
1
llE
l
Screw Skrue

1
motor
320 1 l l E / w e a r disc Slidskive
033

1
l
llE Plug screw Propskrue
332 1 1IE ' K e y Feder
045 llE Gasket Pakning
344 / 1 llE Shim, set Mellernlzg, s z t
4lE

21E
Nut

Stud
Matrik

Tap
356 1 1 /I Silastene Silastene

11E 0-ring 0-ring

368 1 1lE 0-ring only valid for
electronic actuator
0-ring aov. kun til
elehronisk regulator
1
1IE / Castle nut
l
Kronernatrik 381 ( 1IE / Actuator, electronic Eiehronisk regulator

1IE
! Split pin Split 393 1 1 IIE Shutdown solenoid Shutdownspole

1IE 1 Shutdown
( solenoid
Shutdownspole 403 1 1 llE Governor, Europa Regulator, Europa

1IE Governor, Woodward Regulator, Woodward

415 41E I Screw Skrue

4lE Screw Skrue

+ item 212 require an + Item nr. 212 krzver
11E 110.3-0.5-1.0mm)
Shim (set 0.1 - t -
Mellernl~g( s ~0,1
0,3-0,5-1,Omm)
individual matching en individuel tilpasning
(by shims) b e f o r e (rned m e l l e m l ~ g )f ~ r

IIE 1 Disc Skive

mounting, contact,
MAN BBW, Holeby.
montering,kontaktMAN
B&W, Holeby

1E Ball bearing Kugleleje

TIE Bevel gear wheel Konisk tandhjul

1E Key Feder
I
1E ' Castle nut Kronemotrik

1E

1/E

2E
l stud
Split pin

Housing
Split

Hus

Tap

2E Pin Stift

1lE Plug Prop

1IE Screw Skrue

1IE Axle journal Akseltap

11E Bush B~lsning

/ 1
I 1
297 lE Bevel gear wheel Konisk tandhjul

307 llE Gear wheel Tand hjul

When ordering spare parts, see also page 500.50. Ved bestilling af resewedeie, se o g s i side 500.50.
= Only available as part o f a spare parts kit. = Kun tilgzengelig som en del af et reservedelsszet.
QtyIE = QtyIEngine QtyE = QtylMotor
Qtyll = Qtyllndividual Qtyll = Qtyllndividuelt

99.08 - ESO
 Plate
Page 1 (2) Regulating Device 50902-04H

98.45 - ESO 0406

-
-- -- -
E E*-
L 7-
---FP
-
-

-KcTE7s
 ZJMD -
Plate
50902-04H Regulating Device Page 2 (2)

Item
No Qty Designation Benazvnelse Qty I
l
Designation Benzvnelse

11C Bearing bracket, com- Konsol, komplet inkl. 351 11E Shaft, 8 cyl. engine Aksel. 8 cyl. motor
plete incl. bush basning
363 TIE Shaft, 9 cyl. engine Aksel, 9 cyl. motor
2lC Screw Skrue

040 ( l/C 1
I
Lever Arm
I
052 / l 2lC Clamp screw Skrue
I
064 / l1C /Spring Fjeder
I
l11 I 1 llE Pull rod, complete Trekstang. komplet
l
123 1 I 11E Lever Arm
l
135 1 I I E lGovernor arm Regulatorarm
l I
I l 'lEScrew
Skrue
I l
I6O 1 lScrew
21E
11C Adjusting screw
Skrue

Justeringsskme
I I
1/E Stop screw Stopskrue

1E Bracket Konsol

21E Washer Skive

Spring pin Fjederstift

14/E 5 cyl. engine 5 cyl, motor
16/E 6 cyl. engine 6 cyl. motor
17lE 7 cyl. engine 7 cyl. motor
20/E 8 cyl. engine 8 cyl. motor
221E 9 cyl. engine 9 cyl. motor

Nut Matrik
5 cyl. engine 5 cyl. motor
6 cyl. engine 6 cyl. motor
7 cyl. engine 7 cyl. motor
8 cyl. engine 8 cyl. motor
9 cyl. engine 9 cyl. motor

Skrue

280 1 l/E 1 Bracket Konsol

292 1 IIE I Lever, complete Arm, komplet

302 I 1IE 1
Cylinder, complete Cylinder, kornplet

314 I l1E I
Shaft. 5 cyl. engine Aksel, 5 cyl. motor

I I
/ 1
326 IE Shaft, 6 cyl. engine Aksel, 6 cyl. motor

338 1E Shaft. 7 cyl. engine Aksel, 7 cyl. motor

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se o g s i side 500.50
= Only available as part of a spare parts kit. = Kun tilgengelig som en del af et reservedelsset.
Qty/E = QtyIEngine QtyIE = QtyIMotor
Qty.lC = Qty./Cylinder Qty./C = Qty./Cylinder

98.45 - ESO
 ZJMD - B&W

Plate
Page I (4) Instruments 50907-03H

97.51 - ESO 0406 =m

-L=--
=a--=
=
GENERATING SETS
 Plate
50907-03H Instruments Page 2 (4)

-= ' - --
A
-=.E
G =
i--=- 0406 97.51 - ESO
CENERATffi SETS
 ZJMD -
Plate
Page 3 (4) Instruments 50907-03H

97.51 - ESO 0406 -- ---

---
E
- - -- =Cp-CP--=

%&
-T
-~G?%?'s
 ZJMD - B&W

Plate
50907-03H Instruments Page 4 (4)

97.51 - ESO
 Plate
Page 1 (2) Level Switch in Oil Sump (LALILAH 28)

97.37- ESO 0406 --

------
- ---
.- C D ---I
--=c---

EI~~~R~ATKc'I~s
 ZJMD - B&W

Plate
50920-02H Level Switch in Oil Sump (LALILAH 28) Page 2 (2)

F': ( Qty Designation

l Red. adaptor
Ben~vnelse
-
F' : ~ Qty 1 Designation Ben~vnelse

2/E Red. adapter

4/E 1 Screw S krue

S/E l Nut Matrik

liE Plate Plade

1/E 1 Pipe for level switch Rar for nivaeukontakt

1/E 1 Level switch Niveaukontakt

l
1IE

1IE
l Pipe for level switch

Level switch
Rar for nivaeukontakt

Niveaukontak-t
I

0-ring

1/E Dipstick, complete Pejlestok, kornplet

incl. item 157 inkl. item 157

1/E 1 Gasket Pakning

I
182 2/E Red. adaptor Red. adapter

194 11 Glue Lim

1
l

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs5 side 500.50.
= Only available as part o f a spare parts kit. = Kun tilgzengelig som en del af et reservedelss~t.
QtyIE = QtylEngine Qty/E = Qty/Motor

97.37 - ESO
 MAN
il B&W e

Plate
Page I (2) Fuel Oil Leakage Alarm (LAH 42) 50925-02H

98.36 - ESO 0406

 MAN '$
B&W i

Plate
50925-02H Fuel Oil Leakage Alarm (LAH 42) Page 2 (2)

Item
Designation Benzvnelse No. Designation Benzvnelse
1

Fuel oil leakagealarm, Br.oliel~kagealarrn.

cornpiete kornplet

Il
Flange
Flange

l
Gasket Pakning
l
Level switch Niveaukontakt
l
058 1 1 liE l e d . adaptor Red.adapter
l
Reparationsszt for
running in filter indkorselsfilter

286 ( 4/E l Screw Skrue

l
l
Red. adaptor

Pipe for level switch Rnr for niveaukontakt

Nut Mntrik

0-ring 0-ring

Packing ring Pakningsring

Plug screw Propskrue

Packing ring Pakningsring

Plug screw Propskrue

Packing ring Pakningsring

Plug screw Propskme

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele. se ogsi side 500.50
= Only available as part of a spare parts kit. = Kun tilgengelig sorn en del af et reservedelss~t.
QtyIE = QtyIEngine QtyE = Qty/Motor

98.36 - ESO
 ZJMD - B&W

Plate
Page 1 (2) Terminal BOX 50935-O2H 1

Potentiometer for static pressure

/ 0.1 barlstep

lillr
U-,
..........s
4,
* b ....-........
.........
AI =I
<,
da....*

01 b......
m,,.
mBn&I
:
....B.......i
m

--l1

1
ONIOFF Switch & Fuse's

98.44 - ESO ---

C
-- =A
- - - --
--
-- =---=p---2

CENE3ATIVC SETS
 ZJMD - E&W

Terminal Box
I Plate
Page 2 (2)
l
Item I Item
No Qty Designation Ben~vnelse No Qty Designation Ben~vnelse

015 1 11E
l
Operation box ( 0 8 ) Operation box (OB)

1 1IE I Monitor ternp.lpress.

(MTP)
Monitor temp./tryk
(MW

OJ9 i 1!1IE

1IE
Monitor exh. gas
temp. (MEG)

Safety system (CPU)

Monitor udst.gastemp.
(MEG)

Sikkerhedssystern
(CPU)

052 2lE 'Base socket Sokkel

064 1IE
1 Base modul (MB) Basernodul (MB)

076

123
1IE

11E
i l10 modul

Fuse2.A
110 modul

Sikring 2A

135 1IE Panel ( A l ) Panel (AI)

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsB side 500.50.
= Only available as part of a spare parts kit. = Kun tilg~ngeligsorn en del af et reservedelssaet.
- QtylE = QtylEngine QtyIE = QtyIMotor

0406 98.44 - ESO

 Plate
Page 1 (2) Digital Speed Control, Setpoint Programmer 50945-01 H

700 SETPOINT
I

--
OF;-- Q l

L-
;
l
i ~

CPU OK

701 DIGITAL SPEED CONTROL 1

97.45 - E 0 0 0406 =-
---
-- --
- -- -
E E-
--
= =

CENERATNC SErS
 Plate
50945-01 H Digital Speed Control, Setpoint Programmer Page 2 (2)

Item
No / Qty 1 Designation Benzvnelse 1 Qty Designation Benzvnelse

Digital speed Digital speed

control control

Setpoint Setpoint
programmer programmer

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsa side 500.50.
t = Only available as part o f a spare parts kit. = Kun tilgzngelig som en del af et reservedelss~t.
QtylE = QtylEngine QtylE = QtylMotor
QtylQ = QtylPlant QtyIQ = QtyIAnlzg
 Plate
ZJMD - 6ih
Page 1 (2) Alarm Panel 50946-01 H

General

1 l! LvgL"lm&
D A H 62
g2S le-q '
L
CYe-W:
SA- 2. r 1
I

( (/ fig' er- ~s !m:.

T c oute! W+ E! L Je: ?%em hitwe
sx 32 iii

I
High din p m s . h& oil Lav lub. ol level base
firer PDAH 21-22 hame M 2 8

hlub oil oress TC

n hlub d kwl base

I
 MAN
=&'We

Plate
50946-01H Alarm Panel Page 2 (2)

Genera l

F' : 1 1
Qty Designation Ben~vnelse
Item
no
l
Qty l
l
Designation Ben~vnelse

015 1/E Alarm panel Alarm panel

027 l/E i5pol8111B 5 p01 8113 B

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se 0gS5 side 500.50.
;
= Only available as part o f a spare parts kit. = Kun tilgzngelig som en del af et reservedelssaet.
QtylE = QtylEngine QtyE = QtyiMotor

l
F
- E==== 0406 98.40 - EOO-ny
GENEi?AlTJCSETS
 Plate
Page 1 (2) Output Module

General

0 0

OUTPUT MODULE -
-
-

J11 J13 J6 J7 J2 J3 J1 J14

-*W- b - o M - EzE3EaE3
J12 J4 J5 JB J9 J10
Coooowowibo.--- EEEZEE5

0 0
 Plate
50947-03H Output Module Page 2 (2)

General
Item Item l
no Qty Designation Benawnelse no Qty / Designation Benavnelse

083 1lE Panel Sarniekasse

095 1/E Output module Udgangsrnodul

105 1/E Resistor Modstand

117 3/E 3 poltype 8113 B 3 pol type 81138

129

130
1/E 4 pol type 81 13 B

2/E j6 poltype 8113 B

4 pol type 81 13 B

6 pol type 8113 B

l 1
I /
l

,
142 7/E , 1 0 p o l t y p e 8 1 1 3 B 10p01type8113B
l
201 31E ;Cable union Kabel forskrun~ng

213

225

237
31E

21E

2/E
i Nut

Cable union

Nut
Motrlk

Kabel forskmning

Mertrik

250 l/E 12 pol type 8113 B 12poltype 8113 B

'
l

l l
l
l

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se o g s i side 500.50.
= Only available as part of a spare parts kit. = Kun tilgzngelig som en del af et reservedelssaet.
QtylE = QtylEngine QtylE = QtylMotor
 ZJMD - €3&W

Plate
Page 1 (2) APM Motor Control 50948-01 H
50948-01 H APM Motor Control Plate
Page 2 (2)

Item
No Qty Des~gnation Ben~vnelse Benavnelse

016 1/E APM motor control APM motor control

l
l
1 l
l
l
1 I

,
,l

l
i
i l I
I
l
l
1
1
i
l
I
l

When ordering spare parts, see also page 500.50. Ved bestilling af resewedele, se ogsi side 500.50.
= Only available as part o f a spare parts kit. = Kun tilgzngelig som en del af et rese~edelsszt.
QtylE = QtylEngine QtylE = QtyIMotor
 ZJMD - B&W

Plate
Page I (2) Valve Control BOX 50949-01 H

General

l
ENGINE 1 EK!C 2

I xo: XI: X?. 1

 MAN'!.
;, E & W SE: ZJMD - B&W

Plate
50949-01 H Valve Control Box Page 2 (2)

General

'21 1 Qty Designation Benavnelse 1 1Qty Designation Ben~vnelse

l
l

011 2/E Pilot lamp, yellow Larnpeglas, gul

023 2/E Pilot lamp, blue Larnpeglas, b l i

035 41E 1 Lamp holder Larnpefatning

i
! Glow lamp
'
047 6/E Glodelarnpe

OS9
l
4/E 1
!
Head, black Trykknap, sort

060 41E Body Krop

i
072 4/E No contact block Sluttekontakt

084 10/E Auxiliary relay Hj~lperel~

096

106 1/E
I
10IE Socket

Bridge rectifier
Sokkel

Ensretterbro

118

131
1/E
1 Transformer

12lE Fuse terminal

Transfoner

Sikringsholder

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsB side 500.50.
= Only available as part o f a spare parts kit. = Kun tilg~ngeligsorn en del af et reservedelss~t.
QtylE = QtylEngine QtylE = QtyIMotor

---- - -- --
E=- FE-
= =
cENERATNC SETS
-
0406 98.16 - EOO-ny
 IndrE,"" Crankshaft and Main Bearings 510 /
--
Crankshaft and main bear~nas I

~ I n s p e c t ~ oofn rnaln and guide bearing shells '510-01.05( C 3 H )

' V i ~ r a t l o nd a m ~ e r 510-0k.QO (03H) 1

/crankshaft i
l

/Flywheel with gear rim 5 10S33-5H I

l-
~..~..b r a t i odamperjturning
n wheel 510f!4-04H -
 ZJMD - B&W
Description
Page 1 (1) Crankshaft and Main Bearings
Crankshaft and Main Bearings
The crankshaft, which is a one-piece forging, is
suspended in underslung bearings. The main bea-
rings are of the trimetal type, which are coated with
a running layer. To attain asuitable bearing pressure
and vibration level the crankshaft is provided with
counterweights, which are attached to thle crank-
shaft by means of one hydraulic screws.
At the flywheel end the crankshaft is fitted with a gear
wheel which, through two intermediate wheels,
drives the camshafts.
Also fitted here is a coupling flange for the connec-
tion of an alternator. At the opposite end (front end)
there is a gear wheel connection for lube oil and
water pumps.
Lubricating oil for the main bearings is supplied
through holes drilled in the engine frame. From the
main bearings the oil passes through bores in the
crankshaft to the big-end bearings and thence
through channels in the connecting rods to lubricate
the piston pins and cool the pistons.
98.43- ESO
510.01
Edition 02H
Vibration Damper
A vibration damper is mounted on the crankshaft to
limit torsional vibrations. The damper consists of a
primaryand a secondary part. Betweenthese, groups
of leaf spring packs are arranged, which are clamped
at their outer ends.
These spring packs form, together with the primary
and secondary members, chambers which are filled
with oil. If the exterior member vibrates in relation to
the inner member,the leaf springs are bent and force
oil from one chamber into another, retarding the
relative movement of the two parts and thus dam-
ping the torsional vibration. In order to protect the
leaf springs against overloading, their deflection is
limited by buffers.
The elasticity is determined by careful choise of the
leaf springs, the damping factor by the gap between
primary and secondary members.
 Working Card
Inspection of Main and Guide Bearing Shells 510-01.05
Page 1 (3) Edition 03H

Safety precautions Special tools

Stopped englne Plate no ltem no Note

Shut-off startlng air
Shut-off cooling water
Shut-off fuel or1
E Stopped lub. oil circul.
E Press Blocking - Reset

Description

Dismantling, inspection andlor replacement and

mounting of main and guide bearing shells.

Hand tools
Starting position
Allen key, 12 mm
Socket spanner, 36 mm
Lead hammer
Silastene
Sopaslip

Related procedure

I Criteria for replacement of bearings, 506-01 . l 6

1 1

Manpower Replacement and wearing parts

Working time : 2 hours Plate no Item no Qtyl

Capacity 2 man

Data
Data for pressure and tolerance (Page 500.35)
Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

99.33- ESO L
=
-E==
-7-
ONELXKTYUC SETS
-
 ZJMD - B&W

510-01.OS Inspection of Main and Guide Bearing Shells

Working Card
Edition 03H Page 2 ( 3 )

Preparing for Dismantling of the Main and Dismantling o f the Main and Guide Bearing
Guide Bearing Cap

l) Dismount crankcase covers in front and 6) Fit the lifting handle, (Plate 52010, Item 035),
opposite the bearing concerned. so as to support the bearing cap.

2) Turn the engine until the crank is in a conven- 7) Work the main bearing cap loose from the
ient possition for carrying out the work. engine frame with a lead hammer or similar.

3) Mount the hydraulic tool and loosen the brac- 8) Lift the main bearing cap a little and unscrew
ing stud nuts, see fig I . For operating of the the bearing stud nut.
hydraulic tool, please see working card 520-
0 1.05. 9) Lift out the bearing cap from the engine.

Note: When the removing the bearing cap for the

guide bearing, be carefull not to loose the thrust
washers down in the oil pan.w

Dismantling o f Main and Guide Bearing

Shells

10) Remove the bearing shell from the bearing

cap.

l ) Fit the tool for the upper main bearing tool, for
dismantling of upper main bearing shell, in the
lubricating hole in the crankshaft and turn out
the upper bearing shell by turning the crank-
shaft, see fig 2.

Fig 7 Mount the hydraulic tool and loosen the bracing stud
nuts.

4) Mount the hydraulic tools and loosen the main

bearing stud nuts, see fig I.

5) Dismount the hydraulic tools and slacken the Extractor

nuts somewhat. for tool

Fig 2 Tool for removal of upper main bearing shell.

F=aF--===
~7~-TF3C5-e5 0406 99.33 - ESO
 Working Card
Inspection o f Main and Guide Bearing Shells 51 0-01 .OS
Page 3 (3) Edrtion 03H

Cleaning
12) Clean all machined surfaces on frame, bearing
cap, stud, nuts and bearing shells.
I n s p e c t i o n o f M a i n a n d G u i d e Bearing Shells
M o u n t i n g of the M a i n a n d G u i d e B e a r i n g
Ca P
17) Raise the bearing cap into possition with lifting
tool. Coat the bearing studs with molycote
pasta or similar. Fit the bearing stud nuts and
tighten them by hand.

13) Inspect the bearing shells according to work- Note: When mounting the guide bearing cap, re-
ing card 506-0 l. 16. member to inseri the two thrust washers in the guide
bearing cap.

M o u n t i n g of Main a n d G u i d e Bearing Shells Make sure that the bearing cap and bearing shells
are in the correct possition.
14) Push the upper main bearing shell as far into
possition as possible. 18) Remove the lifting tool for the bearing cap.

Note: Be sure that the shell is turned correct accord-
ing to the locking pieces.
15) Fit the tool for upper main and guide bearing in
the lubricating hole in the crankshaft and turn
in the upper bearing shell by turning thecrank-
shaft.
19) Mount the hydraulic bracingscrews and tighten
up the first step as prescribed on page 500.40.
Foruse ofhydraulic tools, please see working
card 520-01.05.
20) Tighten the nuts for the bearing cap as pre-
scribed on page 500.40.

Make sure the shell enters its correct position then 21) Tighten up the bracing screw to second step,
remove the tool for upper main and guide bearing. please see page 500.40.

16) Insert the lower bearing shell in the bearing 22) Tighten the bearings one at a time.
cap according to the locking pieces.

Lubricate the bearing shell and journal with clean

lubricating oil.

Note: never use oil on the outer side of the bearing.

This side must be dry.

99.33- ESO
 7
-
Working Card
Vibration Damper
51 0-04.00
P a g e 1 (3) Edition 03H

Safety precautions Special t o o l s

k? Stopped englne l Plate no Item no Note

E Shut-off startrng alr
Shut-off cool~ngwater
Shut-off fuel 011
E Stopped lub. 011circul.
E Press Block~ng- Reset

Description Hand t o o l s

Related procedure

1 Manpower Replacement a n d wearing p a r t s

1 Working time : X hours Plate no Item no Qty 1

Capacity 1 man
See plate 51004

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration ofweight (Page 500.45)

98.44 - ESO
 ZJMD - B&W

51 0-04.00 Vibration Damper

Working Card
Edition 03H Page 2 (3)

Together with every main revision of the engine the
damper is to be inspected as well. Generally an
inspection of this kind is to be carried out every 28-
30.000 hours of service together with service and the
replacement of certain parts, which are exposed to
wear.
Note: Regular inspection and supervision of the
damper allows for preliminary planning and to order
spare parts in time.
Allowable Wear
lnner Spring Ends and Groove Flanks
Wear takes place due to lack of oil supply.
Spring packs consisting of two conical spring blades
onlyareclarnped inthe innerstar grooveattheir inner
spring ends, thus producing a slight preload of the
springs. The allowable wear will be attained as soon
as the preload of the springs is not existing any more
and an additional clearance of "z"mm per side
between spring ends and groove flanks occures
(totalling 2 X z mm if one side of spring end rests on
groove flank), see fig 2.

Total wear must not exceed 5% ofthe rope diameter,

see fig l.Independent from wear all rubber rings and
gaskets should be renewed whenever damper is
taken apart.

Note: Because of leakage problems vulcanized rub-

ber rings do not suit this application. Use seamless
rings only.

Fig 2 lnner spring ends and groove flanks

I l

Fig 1 Rubber seal ring

General Working Conditions

N
Oil pressure at oil inlet of damper to be 2,5 bar 2
minimum (u.0.s.) 7F
m
0
N
Ambient temperature from -20" to + 120" C (unless g
otherwise stated).
z
C)

N
0
m
0

98.44 - ESO
 Working Card 510-04.00
Page 3 (3) Vibration Damper Edition 03H

Circularity of Outer Member (correction)

The inner ends of the spring packs or intermediate

pieces might not be exactly circular. An eventuel
divergence from circularity must be corrected to be
less than 0.1 mm in diameter measured between
opposed intermediate pieces. This can be achieved
by hits onto the outside of the clamping ring using a
"soft hammer" or radial hits from the inside. For big
dampers a hydraulic cylinder, applied from inside wiil
be necessary.

If the lateral plates 5 and 7, fig 3 are without a

centering shoulder (to accommodate clamping ring),
lateral plates 5 and 7, fig 3 and clamping ring 3, fig 3
are to be adjusted concentric with a tolerance of
f 0.1 mm.

Appendix

lfwater mixes with the engine oil -especially seawater

-the lubricating properties of the oil will be reduced
rapidly. In case an exceptional amount of water is
detected in the oil supplied to thedamper the remain-
ing oil inside damper is to be replaced by new oil as
well. Even ifthedampershould besupplied with an air
escape nozzle, which provides a small oil flow through
the damper, this oil circulation is not suitable to
exchange the oil volume inside the damper. The
following procedure is to be followed for a total oil Fig 3 Damper
exchange.

a) To emptythedampertotallyturn it by 180" afew

times and make sure that the oil oufflow has
stopped in any position of the damper.

b) Vent damper before it is put into service again.

In case thatthe engine bearings are found to be worn

out because of lub. oil which was or is containing
water, the damper is to be inspected for wear and
corrosion as soon as possible as well. (Total inspec-
tion). See "Allowable wear".

98.44 - ESO 0406 --

-- --- -
-E--

CENRATNC SETS
 Plate
Page 1 (2) Crankshaft

98.41 - ESO 0406 ---

--
m----
---
- -- --
--
- --
------
- --
GENERATBUG SETS
 Plate
51001-03H Crankshaft Page 2 (2)

Item I Item
no Qty (Designation Benzvnelse no Qty Designation Benzevnelse

Krumtap,
5 cyl. engine 5 cyl. motor

03' l IIE Crankhaft,

16 c y l engine
Krumtap,
6 cyl. motor

1IE Crankhaft, Krumtap,

17 cyl. engine 7 cyl. motor

1/E ' Crankhaft, Krumtap,

18 cyl. engine 8 cyl. motor

1/E Crankhaft, Krumtap,

/ 9 cyl. engine
'

9 cyl. motor
l
4/C
1C lindrical pin Cylindrisk stift

2lC N u t Matrik

2lC Bolt Bolt

2/C Counterweight

Plug screw Propskrue

5 cyl. engine 5 cyl. motor
6 cyl. engine 6 cyl. motor
7 cyl. engine 7 cyl. motor
8 cyl. engine 8 cyl. motor
I 9 cyl. engine 9 cyl. motor

1 Plug screw Propskrue

I
J Screw Skrue

1 0-ring

165 1 E 'Cylindrical pin Cylindrisk stift

l l
l77 ( 1iE 1 Cylindrical pin
I
Cylindrisk stift

4~ ! screw Skrue

1/E
i Gearwheel 212 Tandhjul U 2

3/E Cylindrical pin Cylindrisk stift

When ordering spare parts, see also page 500.50. Ved bestilling af resewedele, se ogs6 side 500.50
= Only available a s part o f a spare parts kit. = Kun tilgaengelig som en del af et resewedelssa?t.
QtyIC = QtyICylinder QtylC = QtylCylinder
QtyIE = QtylEngine QtylE = QtylMotor

98.41 - ESO
 Plate
Page I(2) Flywheel with Gear Rim 51003-05H

98.48 - ESO 0406 -

PZ ===
--
- p
--
----- =
-
E-
=
---
-

GENERATNC SETS
- -
 ZJMD -
Plate
51003-05H Flywheel with Gear Rim Page 2 (2)

I Qty

11E
Designation

Flywheel,
5 cyl. engine
Benavnelse

Svinghjul
5 cyl. motor
Item
no

Flywheel, Svinghjul
6 cyl. engine 6 cyl. motor

Flywheel, Svinghjul
7 cyl. engine 7 cyl. motor

1/E Flywheel, Svinghjul

8 cyl. engine 8 cyl. motor

1IE Flywheel, Svinghjul

9 cyl. engine 9 cyl, motor

I
l Z l E Bolt Bolt

1/E Gear rim Tandkrans

l
1ZlE Screw

1ZlE Sleeve
Skrue

Afstandsstykke

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsB side 500.50.
= Only available as part of a spare parts kit. = Kun tilgzngelig som en del af et reservedelss=t.
QtylE = QtylEngine QtylE = QtylMotor

98.48 - ESO
 Plate
Page 1 (2) Vibration Damper / Tuning Wheel

a ,
:c<*-
c .,%

=
,!\',.:,
I..--
;. .:..
\.
*\.
..
.. ,--
v-\, ,:' 9L16124, 1200 rpm

1000 rpm

98.37 - ESO 0406 --

--
I
m
E-'
----v
--
- - --
-
E =-
--
-
CUUERATNG SETS
 Plate
51004-04H Vibration Damper l Tuning Wheel Page 2 (2)

L16124
Item
No. Qty Designation Benavnelse :"I
016 1IE Vibration damper Svingningsd;emper
6cyl.-1200rpm engine 6 cyl.-1200 rpm motor
7cyl.-1000 rpmengine 7 cyl.-1000 rpm motor
7cyl.-1200rpm engine 7 cyl.-1200 rpm motor
9cyI.-1200rpmengine 9 cyl.-1200 rpm motor

028 1IE Intermediate ring, Mellemring, undtagen

except 9cyl.-1200 rpm 9cyl.-1200 rpm motor
engine

041 / 1
llE Spur gear Tandhjul

053
I 1
12/E Screw

1IE Vibration damper

S krue

Svingningsd~rnper
5cyl.-1200rpm engine 5 cyI.-1200 rpm motor

1IE Vibration damper Svingningsd~rnper

8cyl.-1000rpmengine 8 cyl.-1000 rpm motor
8cyl.-1200rpm engine 8 cyl.-1200 rpm motor
9 cyl.-1000 rpm engine 9 cyl.-1000 rpm motor

2/E

1IE
I Screw

Intermediate ring,
Skrue

Mellemn'ng,
9cyl.-1200rpm engine 9 cyl.-1200 rpm motor

l1E Tuning wheel, Afstemningshjul,

6cyl.-1000rpmengine 6 c$.-1000 rpm motor

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se o g s i side 500.50.
= Only available as part o f a spare parts kit. = Kun tilgangelig som en del af et reservedelsszt.
QtylE = -/Engine. QtyIE = QtyIMotor.

98.37 - ESO
I Indexpage
I (I, I Engine Frame and Base Frame 511 ~
/ ~ n g i n frame
e a n d base frame I

Funct~onaltest o f crankcase safetv r e l ~ evalves

f ?5hP-OP.00 102H3 I

/Frame wlth m a n b e a r ~ n g s '51E O L - O ~ H I

'Front-end box '511GEM !

!

/cover on frame $51106-Cr4K I

/Cover on frame IG&-OSH

-- -
f
[Base frame 5221 l - O 2 M l
 ZJMD - E&W t"AN
saw 1
'i

Description 51 1. O l
Page 1 (1) Engine Frame and Base Frame Edition 02H

Engine Frame
The monobloc cast iron engine frame is designed to
be very rigid. All the components of the engine frame
are held under compression stress. The frame is
designed for an ideal flow of forces from the cylinder
head down to the crankshaft and gives the outershell
low surface vibrations.
On the sides of the frame there are covers for access
to the camshafts and crankcase. Some covers are
fitted with reliefvalves which will operate ifoil vapours
in the crankcase are ignited (for instance in the case
o f a hot bearing).
Base F r a m e

Two camshafts are located in the engine frame. The The engineand alternator are mounted on a rigid base
valve camshaft is located on the exhaust side in a frame. The base frame acts as a lubricating oil
very high position and the injection camshaft is reservoirfortheengine.Thealternat~ri~~~n~idered
located on the service side of the engine. as an integral part during enginedesign. This GenSet
is flexible mounted on the foundation with rubber
The main bearings for the underslung crankshaft are elements under the base frame.
carried in heavy supports by tierods from the interrne-
diate frame floor, and are secured with the bearing
caps. These are provided with side guides and held in
place by means of studs with hydraulically tightened
nuts. The main bearing is equipped with replaceable
shells which have the final tolerances.

m
9
*
m
I
S
Ln
Fig l Engine Frame
N

.
Ln
I
 Working Card
Functional Test of Crankcase Safety Relief Valves 511-01.OO
Page 1 ( 2 ) Edition 02H

Safety precautions Special tools

EL Stopped engine Plate no Item no Note
Shut-off startrng alr
Shut-off cooling water
Shut-off fuel 011
Stopped lub. oil circul
m Press Blocking - Reset

Description Hand tools

Functional test of crankcase safety relief valves.

Starting position

Related procedure

Manpower Replacement and wearing parts

Working time : 114 hour Plate no Item no Qtyl
Capacity 1 man
51 106 237 l /relief valve
51106 477 l /relief valve
Data 51 106 524 llrelief valve

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.47 - ESO ----- -

L E i

---m-
-
-
-
= F

-
---=
GGN5%ATO\IC;SETS
 i MAN
L B&W 1. ZJMD - B&W

511-01.00 Functional Test of Crankcase Safety Relief Valves

Working Card
Page 2 (2)
Edition 02H

Functional Testing

Functional testing of the crankcase safety relief

valves cannot be performed during operation of the
engine, but it must be checked during overhauls that
the valve flap is movable.

When Painting
Relief
When painting the engine take care not to block up valve
the safety relief valves with pa~nt.

Check of Opening Pressure

To check the proper opening pressure proceed as

follows:

I) Remove the reliefvalve cover from the engine.

2) Place the cover on the floor with the pressure

area upwards. ~ i Ig Cover with relief vaive

3) Apply a weight at 15 kg on the pressure area.

The relief valve must open under this pres-

sure.

4) Remount the relief valve cover of the engine

If the safety relief valves are actuated, the

engine must be stopped immediately, and it
must not be restarted until thecauseisdetected
and the fault is detected, see also description
503.04, ignition in crankcase.

i E =A=
=
E===-=
-C--=.= = 0406
98.47- ESO
GEN6RATNG SETS
 Plate
Page 1 (3) Front End Box

Lubricating oil cooler,

see plate 51506
350

03.06 - ESO 0406 -

- -- -
- - A -

---m-
----
-
=-=F -
---
GENERPITLNG SETS
 ZJMD - E&W

Plate
51 103-06H Front End Box Page 2 (3)

Itern Itern
no Qty Designation Benievnelse no Qty Designation Benaevnelse

1 I
11
014 1/E Front end box Front end box 349 4/E Screw Skrue

026 5/E ( Plate Plade 350 8/E Screw Skrue

038 13lE 1 Screw Skrue 362 2/E Flange Flange

051 1 1 6/E Washer Skive 374 2/E Gasket Pakning

06)
075
I Il 41E
l/E
Nut
Flange
Mstrik

Flange
386

398
16/E

6/E
Screw

Intermediate piece
Skrue

Meliemstykke

087 1 I 3/E Screw Skrue 408 12/E 0-ring 0-r~ng

099 1 I 3/E Washer Skive 421 1IE Housing for

lub. oil separator
Hus for
smoreolieseparator

log
110
'IE l1 I
4/E ( Screw
Plade
433 12/E Screw Skrue

I 1
Skrue
445 1/E 0-ring 0-ring
122 2iE Plug screw Propskrue

134 / I ZE Packing ring Pakningsring

457 1/E Bracket for by-pass
centrifugal filter
Konsol for centrifugal
by-pass filter

lI II Thermostatic Terrnostatelement 469 4/E Screw Skrue

element for lub. oil for smsreolie
ZE 470 1E Plug screw Propskrue
l58 6/E Sleeve Bcrsning

171 / 6E ( Retaining ring Sikringsring

482 1/E Packing ring Pakningsring

183 ( l/E I Plate Piade

494 ?/E Cover Dgksel

195 1 4/E 1 Stud Tap

504 ZE 0-ring 0-ring

205 / l/E 1 Gasket Pakning

516 8/E Screw Skrue

217+ I l/E I Flange Flange

528 8/E Spring washer Fjederskive

229 / l/E 1 Gasket Pakning

541

553
1IE

1/E
Spring

Piston
Fjeder

Sternpel

254 ( 14/E 1 Screw Skme

565 9/E Screw Skrue

266 1 1 l/E Housing Hus

577

600
l/E

15/E
0-ring

Screw
0-ring

Skrue
Thermostatic Terrnostatelement
element for HT for HT kslevand 612 4/E Screw S krue
cooling water
624 1/E Screw Skrue
Thermostatic Terrnostatelernent
element for L T for LT kslevand 636 1IE Thrust piece Trykstykke
cooling water
648 1/E Covering plate D~kselplade

)01 1 l Gasket
Pakning

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs5 side 500.50
= Only available as part o f a spare parts kit. = Kun tilgzngelig sorn en del af et resewedelssa?t
Qty/E = QtylEngine Qty/E = QtyIMotor

03.06 - ESO
 Plate
Page 3 (3) Front End Box 51 103-06H

ltem ltem
no Qty Designation Ben~vnelse no Qty Designation Benawnelse

661 1/E Setting screw Skrue

673 1/E Nut Matrik

685 1/E Cover Dzksel

997 4/E 0-ring 0-ring

998 4/E Sleeve B~sning

+ To be used i f cen- + Anvendes hvis ikke

trifugal by-passfilter centrifugal by-passfil-
i s not mounted ter er monteret

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsa side 500.50.
= Only available as part o f a spare parts kit. = Kun tilgiengelig sorn en del af et reservedelssiet.
QtylE = QtylEngine QtylE = QtylMotor
 MAN
ZJMD - / B d

l Plate
Page 1 (2) I Covers on Frame ( 51106-04H 1

98.48 - ESO 0406 --

-
----- --
==
-- C

p
-- -
- W-
-
-
-
-
--G
-

CEbEQATNCSETS
- - -
 Plate
51106-04H Covers on Frame Page 2 (2)

E
' rI Qty Designation Benawnelse
Item
No Qty Designation Benavnelse

IIC Cover Dzksel D~kselplade,

7 cyl. engine 7 cyl. motor

D~kselplade.
Cover Dzksel 8 cyl. motor
31E 5 cyl. engine 5 cyl. motor

1
3/E 6 cyl. engine 6 cyl. motor llE Cover plate, Daekselplade,
4/E 7 cyl. engine 7 cyl. motor 19 c y ~engine
. 9 cyl. motor
51E 8 cyl. engine 8 cyl. motor
5/E 9 cyl. engine 9 cyl. motor 404 l / C (Cover
l
Stud Tap
5 cyl. engine 5 cyl, rnotor
1IC
1 Cover 6 cyl. engine 6 cy rnotor

225 1 1 Coverwith relief valve

2/E i 5 cyl. engine
Dzkselmed relietveniil
5 cyl. motor
7 cyl. engine
8 cyl. engine
9 cyl. engine
7 cyl. motor
8 cyl. motor
9 cyl. motor
31E j 6, 7, 8 cyl. engine 6, 7, 8 cyl. motor
41E 19 cyl. engine 9 cyl. motor Cover

Cover Dzksel

Screw Skrue Valve flap for safety Ventilklap for sikker-

5 cyl. engine 5 cyl. motor valve hedsventil
6 cyl. engine 6 cyl. motor
7 cyl. engine 7 cyl. motor

Washer l
103lE 5 cyl. engine
8 cyl. engine
9 cyl. engine
8 cyl. motor
9 cyl. motor

Skive
5 cyl. motor 490
11 1/D

4/D
Compression spring
(right

l Distance pipe
Fjeder

Afstandsstykke
1161E 16 cyl. engine 6 c y motor
129IE ! 7 cyl. engine 7 cyl. motor 500 410 C o a c h bolt Bolt
/
14ZE 8 cyl. engine
155E 19 cyl. engine
8 cyl. motor
9 cyl. motor 512 , , 4/D Self locking nut Selvlisende mntrik

Cover Dieksel Washer Skive

0-ring 0-ring Self locking nut Selvlisende mstrik

5 cyl. engine 5 cyl. motor
Cover Dzksel 6 cyl. engine 6 cyl. motor
7 cyl. engine 7 cyl. motor
0-ring 0-ring 8 cyl, engine 8 cyl. motor
9 cyl. engine 9 cyl. motor
Cover Dieksel

0-ring 0-ring

Cover Dieksel

Cover plate, Dzkselplade,

5 cyl. engine 5 cyl. motor

Cover plate, Diekselplade,

6 cyl. engine 6 cyl. motor

When ordering spare parts, see also page 500.50. Ved bestilling af resewedele, se o g s i side 500.50.
= Only available as part o f a spare parts kit. = Kun tilgiengelig som en del af et reservedelss~t.
QtyIE = QtyIEngine QtyE = QtylMotor
QtylC = QtyICylinder Qty/C = QtylCylinder
QtylD = QtyICover QtylD = QtylDiekseI

98.48 - ESO
 Plate
Page 1 (2) Cover on Frame 1 51106-06H 1

98.48- ESO 0406 --

--- --
--
E
-v----
- - --
=-
= -
F

a E R A T N G SETS
 ZJMD - BeW

Plate
51106-06H Cover on Frame Page 2 (2)

1 ken
1 Des~qnat~on
. . Benavnelse
Qty Designation Benavnelse no
l
-
Dzeksel

18/E / Screw Skrue

l
81E Screw 1 Skrue

Locking spring LBseQeds:skive

washer

4/E
I Screw

4/E 1 Thrust washer

Skrue

Flederskive

1/E
I Cover Dzekse!

8/E l Screw Sk;ue

!
81E Lock washer Lisesktve

E
I
1/E
i
' Sealing ring

cover
T~tningsring

D~ksel
i
4lE Screw Skrue

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs& side 500.50.
= Only available as part o f a spare parts kit. = Kun tilgaengelig sorn en del af et reservedelsszet.
QtylE = -/Engine Qty/E = QtyIMotor

98.48 - ESO
 ZJMD -

- 163

Level switch in oil sump,

see plate 50920

98.45 - ESO 0406 -

--
-i =.+L=
- - - - - m
-- --
FE=-

CENERATNGSETS
 Plate
51111-02H Base Frame Page 2 (2)

F Item
no Qty i Designation

5 c y ~engine
. Bundramme
5 cyl. motor
Qty
l
I Designation
l
Benaevnelse

O3I l IIE

?/E
l
Base frame,
6 cyl. engine

Base frame,
7 cyl. engine
Bundramme,
6 cyl motor

Bundramme,
7 cy!. motor

055 1 1 11E Base frame,

8 cyl. engine
Bundramme,
8 cyl. motor

Base frame, Bundramme,

9 cyl. engine 9 cyl. motor

079 l 7lE
1
Screw

080 41E S c r e w Skrue

092 i 4~ l Nut
l
Motrik

1
Screw Skrue
30lE 15 cyl. engine 5 cyl. motor
341E 1 6 cyl, engine 6 cyl motor
38lE / 7 cyl. engine 7 cyl. motor
42fE ' 8 cyl, engine 8 cyl. motor
4SlE 19 cyl, engine 9 cyl. motor
l
1 Disc Skive
30lE / 5 cyl. engine 5 cyl. motor
341E 6 cyl. engine 6 cyl. motor
38lE 17 cyl. engine 7 cyl. motor
42fE i 8 cyl. engine 8 cyl. motor
46lE l 9 cyl. engine 9 cyl. motor

151 1 11E ( Packing ring Pakningsnng

Plug screw Propskrue

When ordering spare parts, see also page 500.50. Ved bestilling af resewedele, se 0gsa side 500.50.

= Only available as part o f a spare parts kit. = Kun tilgzngelig som en del af et reservede1ss;et.
QtylE = QtylEngine QtyIE = QtylMotor

0406 98.45 - ESO

 l ~ u r b o c h a r ~system
er i522.02 ( Q 5 H )

j ~ v e r h a u of
l charging alr cooler ;512-62.00( O 2 W )
1
'I ~ x h a u s pipe
t compensator 5;;2-0l,19( Q Z H ) l
7
l
;Cleaning the turbine, dry clean~ng 512-10.0I;( 0 3 H ) 1

k h a r g i n g air cooler '5LZO',-GES

:Exhaust pipe arrangement
{Mountin3 of turbocharaer 54223-07~

! I
;Charge air pipes S Z ~ ~ G - G ~ E
 Description 512.01
Page 1 (2) Turbocharger System Edition 05H

Water wash~ng P9
compressor side
(hand injector)

ao
E W
S 8 1 l

.I

Drain from
turbocharger-
-- I
(n-
Alternator

Charge air to Lambda controller

l

- outlet
\charge air to lub. oil (see compressed air diagram)
regulating valve for TC
Funnel delivered P6 (see lub. oil diagram)
by customer

Fig. 1. Diagram for Combustion Air System

Turbocharger System The charging air cooler is a compact two-stage tube-

type cooler with a large cooling surface. The high
The turbocharger system of the engine, which is a temperature water is passed through the first stage
constant pressure system, consists of an exhaust of the charging air cooler and the low temperature
gas receiver, a turbocharger, a charging air cooler water is passed through the second stage. At each
and a charging air receiver. stage of the cooler the water is passed two times
through the cooler, the end covers being designed
The turbine wheel of the turbocharger is driven by with partitions which cause the cooling water to turn.
the engine exhaustgas, and theturbine wheel drives
the turbocharger compressor, which is mounted on The cooling water for the low temperature stages of
the common shaft. The compressor draws air from the charge air is controlled by the scavenging pres-
the engine room through the air filters. sure to ensure sufficient scavenging temperature for
9
d
m
burning HFO.
5
m The turbochargerforces the airthrough the charging
air cooler .to the charging air receiver. From the From the exhaust valves, the exhaust gas is led
I
charging air receiver the air flows to each cylinder through to the exhaust gas receiver where the
W through the inlet valves. pulsatory pressure from the individual cylinders is
N
0
W
0
equalized and passed on to the turbocharger as a
constant pressure, and further to the exhaust outlet
and silencer arrangement.

99.37 - ESOS 0406

 ZJ M D - B&W

The exhaust gas receiver is made of pipe sections,

one for each cylinder, connected to each other bv
means of compensators to prevent excessive stress
in the pipes due to heat expansion.

To avoid excessive thermal loss and to ensure a

reasonably low surface temperature the exhaust
gas receiver is insulated.

l l

Fig. 2. Conslant Pressure Turbocharger Sysrern

---*==
--
L
-- --
- ----
S-
---
-
- p - - - -
-
a406 99.37 - ESOS
CENEFATUUC SETS
 Working Card
Page 1 (4) Overhaul of Charging Air Cooler 512-01 .OO
Edition 02H

1 Safety precautions Special tools

Stopped engine Plate No ltem No Note

E Shut-off startrng air
Shut-off cooling water
Shut-off fuel oil
Stopped lub. oil circul.

Description H a n d tools

Overhaul of charging air cooler.

Related p r o c e d u r e

Manpower Replacement a n d wearing p a r t s

Working time : 3-4 hours Plate No Item No Qtyl

Capacity 2 men

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

01.30 - ESO -----

--
--
=W ----
-----
- ---
L==

GENERATING SETS
 ZJMD - E&W

1 512-01.00
Edition 02H
1 O v e r h a ~of
~ l Charging Air Cooler
Working Card
Page 2 (4)

The charging air cooler is normally cleaned and

overhauled at the intervals indicated in the "Planned
Maintenance Program",or if observations prove that
the cooler does not work adequately, see section
502.

Dismounting of Charging Air Cooler

1) Turn off the cooling water inlet and outlet

valves.

2) Remove the charging air pipe, see fig 1. 1 1

Fig I Assembly of charging airpipe

1 Lifting hole-,

Top plate ( 5 )

I
Screw (2) 1"4- L Gasket (6)
End cover (3)

Fig 2 Charging air cooler

E=-
= r---
F-====
CENEFATING S E T S
- 0406 01.30 - ESO
 Working Card
~ l Charging Air Cooler
O v e r h a ~of 512-01.OO
Page 3 (4)
Edition 02H

Cleaning and Inspecting

7) Clean the cooler element of the water and air

sides.

After using cleaning agents the manufacturing

recommendation must be followed.

The greatest care must be exercised when

dismantling cleaning and mounting the cooler
element, as the thin fins of the tubes cannot
stand impacts and pressure.

Inevertheless the metal is bent, it should be

Fig 3 Removal of charge air cooler
3) Mount the lifting tool, see fig 3.
4) Attach a tackle hook to the lifting tool bolt and
tighten the wire.
5) Lift and pull the air cooler out of the cooler
housing and place it on a couple of wooden
planks on the floor.
6) Remove screws (2) and end cover (3) reversal
chamber (4), and top plates (5), see fig 2.
carefully straightened, as bent fins will in-
crease the pressure drop across the cooler
considerably.
Should one or more cooler tubes become
leaky itlthey must immediately be made tight,
either by expanding the tube ends into the tube
plates or by blanking of the tube(s) concerned
with plugs.
It is important that the charging air cooler is not
leaky as any water that leaks in will be carried
together with the air into the cylinders where it
will damage valves, piston rings, and cylinder
liners.
8) Also clean the end cover and coat it on the
inside with an anticorrosion agent.

9) Fouling and deposition in the pipes can be

removed with a hand or machine operated
circular steel brush.

01.30 - ESO
 ZJMD - E&W

512-01 .oo Overhaul of Charging Air Cooler

Working Card
Page 4 (4)
Edition 02H

Mounting of Charge Air Cooler

10) Renew gaskets (6) and (7) before assembling

c
endcover (3) reversal chamber (4) and top
plate (5). See fig 1.

Note: Before mounting the air coolertheo-ring at the

water connections must be replaced, see fig 4, pos.
l.

l ) Lift the air cooler by the lifting tool and push it

carefully half-way into its housing.

12) Remove the lifting tool and push the air cooler
into place.

13) Mount the screws see fig 2, pos. l and the ~ i 4g Mounting ofchargingaircooler
charge air pipe, see fig I .

Out of Service Periods.

At longer periods out of service, recommendations

for the entire system is followed. Please see section
501.

01.30 - ESO
 8 & ~ ~ ~ "Y~ 2 ~ , 4

/P. "c;.'
1 MAN '':
$ B&W t

Working Card 512-01 .l

0
Page 1 (2) Exhaust Pipe Compensator Edition 01 H

Safety precautions Special tools

Stopped engine Plate No Item No Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Stopped lub. oil circul.

Description Hand t o o l s

Starting p o s i t i o n

Related p r o c e d u r e

Manpower Replacement and wearing parts

Working time : % hour Plate No Itern No Qty.1

Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

97.40 - ESO
 512-01.l
0 Exhaust Pipe Compensator
Working Card
Page 2 (2)
Edition 01H

Description

To minimize toxic gases in the engine room and to

keep the exhaust gas insulation in good condition, it
is necessary to keep the exhaust pipe compensators
tight.

1) Start the engine

2) Feel and smell for any leak in the exhaust gas

pipe compensators.

Note: If any leak is discovered the compensator in

question must be renewed.

---
- -----
--
==E E
- - --
---
=-
-
97.40 - ESO
Ca'ERATWG SETS
 Working Card
Cleaning the Turbine, dry cleaning 512-10.00
Page 1 (2)
Ed~tion03H

Safety p r e c a u t i o n s Special tools

Stopped engine Plate No Item No Note.

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Stopped lub. oil circul.

Description Hand tools

Cleaning the turbine.

Starting p o s i t i o n

Related p r o c e d u r e

Man power Replacement and w e a r i n g p a r t s

Working time : - hour Plate No Item No Qty.1

Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

97.50 - ESO
 ZJMD - 13&W

Working Card
Page 2 (2) Cleaning the Turbine, dry cleaning
1 512-10-00
Edition 03H 1

5-7bar
1 Stop valve
2 Container
3 Valve
$ Working air

Fig. 2. Dry cleaning

Dry cleaning
Depending on the type of engine and turbocharger,
the arrangement of items may also differ somewhat
from that shown in the schematic.
Fill the container (2) with granulate. The amount
depending on the type of turbocharger;
NR12, NR14, NR15,
NR17, NR20 .................................. 0.3 liter

Appropriate cleaning materials are granulates from NR24: IVR26 .................................. 0.4 liter
nut shells or activated charcoal of a grain size of 1
mm (max. 1.5 mm). NR29, NR34 .................................. 0.5 liter

Connect to the working air system (4).

Cleaning sequence
Please also consult the data plate.
The cleaning is to be carried out at high engine load,
min. 75 % MCR.
Before connecting the "blow gun" open the stop
valve (1) and check that the passage is not blocked.
Connect the "blow gun" to valve (1) and open valve
(3). Then open valve ( l ) slowly until a hissing sound
indicates that the granulate is being injected. Injec-
tion period: approx 2 min.
Dry cleaning must be performed at all injection
connections (if more than one).
(U

Close the valve again. 9

W

97.50 - ESO
 Plate
Page 1 (2) Charging Air Cooler 1 51201-06H

97.43 - ESO ---

- - - - - m
S
E
----
!=
,=
-

CENERATNG SETS
51201-06H Charging Air Cooler
l Plate
Page 2 (2)

Qty I Designation Benzvnelse Benzvnelse

l
2lK ( T o p plate Topplade

8/K Screw Skrue

1IK ' 0 ring 0-ring

l -
8/K
i Screw Skrue

054 ' 4/K Plug screw Propskrue

066 4/K ' Cu-washer Cu-skive

078 4/K Screw Skrue

091 16/K Washer Skive

101 16/K Screw Skrue

113 1 l/K
l
Gasket end cover Pakning endedaksel

125 ( 1/K 1 End cover Ended~ksel

137 ?/K 1
I
Cooler block K~lerblok

149 1/K ! Reversing cover Vendekarnrner

!
150 1 IIK 1 Gasket
! reversing cover
Pakning
vendekarnrner
l l
162 ( 1/E 1 Charging air cooler, Charging air cooler,
/ complete kornplet
,
!
l
i

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se o g s i side 500.50.
= Only available as part o f a spare parts kit. = Kun tilgiengelig sorn en del af et rese~edelssiet.
QtylK = QtylCooler QtyIK = QtylKaler
Qty.lE = QtyJEngine Qty.lE = Qty./Motor

97.43 - ESO
 MAN "i.
f S&W 2

Plate
Page 1 (2) Exhaust Pipe Arrangement

Turbocharger arrangement,
see plate 51203

99.09 - ESO -
-- - -
-- -
CWERATNG SETS
 ZJMD - B&W

Plate
51202-04H Exhaust Pipe Arrangement Page 2 (2)

Qty Designation Benawnelse Qty Designation Benavnelse

11E Cover

Gasket
Dzksel

Pakning
I
5 cyl. engine 5 cyl. motor
6 cyl. engine 6 cyi. motor
7 cyl, engine 7 cyl. motor
8 cyl. engine 8 cyl. motor
9 cyl. engine 9 cyl. motor

Screw Skrue
441E 5 cyl. engine 5 cyl. motor
52lE 6 cyl. engine 6 cyl. motor
601E 7 cyl. engine 7 cyl. motor
68lE 8 cyl. engine 8 cyl. motor
7ZE 9 cyl. engine 9 cyl, motor

1Nut Motrik
5 cyl. engine 5 cyl. motor
6 cyl. engine 6 cyl. motor
7 cyl. engine 7 cyl. motor
8 cyl. engine 8 cyl. motor
9 cyl. engine 9 cyl. motor

llC
l Exhaust manifold Udstodsmanifold
I
11C Compensator Kornpensator
I
1IC Clamping strap 212 Holder 212
i
ZC Screw Skrue
l

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se o g s i side 500.50
= Only available as part o f a spare parts kit. = Kun tilg~ngeligsom en del af et reservedelss=t.
QtylE = QtylEngine QtyE = QtylMotor
QtylC = QtylCylinder QtylC = QtylCylinder

99.09 - ESO
 ;MAN ',
i B&W L

Plate
Page I(2) Mounting of Turbocharger 51203-07H

5 cyl. engine (1200 rpm)

6 cyl. engine (100011200 rpm) Turbocharger, see
7 cyl. engine (1000 rpm)
r
1
r"~
l !
- i n c t r ~~ r t i n nhnnk f n r

--/
P F l
I, , Q L l U V L l V l I " V " I \ I V I

!
13_

turbocharger.
d

7 cyl. engine (1 200 rpm) Turbocharger, see

8 cyl. engine (1 00011200 rpm)
9 cyl. engine (1 00011200 rpm)
, >
,,,,,turbocharger.
- book for
instruction
,1

99.06- ESO
&'
@@%-c:<.:".
P?
W
"44
.
MAN ?,
e =&W; Z J M D
Piate
51203-07H Mounting of Turbocharger Page 2 (2)

Item
Qty Designation Ben~vnelse no

4/E Screw Skrue

4/E Lock washer Liseskive

4/E Screw Skrue

4/E Lock washer LBs~skive

l/E Pipe piece for Rarstykke for

5 cyl. 1200 rpm 5 cyl. 1200 rpm
6 cyl. 1000/1200 rpm 6 cyl. 1000/1200 rpm
7 cyl. 1000 r p m 7 cyi. 1000 rpm

1/E 1 Gasket Pakning

Screw Skrue

Socket Muffe

I Packing ring

Turbocharger f o o t for
Pakningsring

Turboladerfod for
7 cyl. 1200 rpm 7 cyl. 1200 rpm
8 cyl. 100011200 r p m 8 cyl. 1000/1200 rpm
9 cyl. 100011200 r p m 9 cyl. 1000/1200 rpm

/ Bolt Bolt

l Casing Hus

Closing cover

Sealing compound Tztningsrniddel

(Silastene) (Silastene)

Pipe piece for Rsrstykke for

7 cyl. 1200 rpm 7 cyl. 1200 rpm
8 cyl. 100011200 r p m 8 cyi. 100011200 rpm
9 cyl. 100011200 r p m 9 cyi. 100011200 rpm

Gasket Pakning

Skrue

Nut Mstrik

When ordering spare parts, see also page 500.50. Ved bestiliing af reservedele, se 0gS2 side 500.50.

= Only available as part o f a spare parts kit. = Kun tilg~ngeligsom en del af et reservedelssEt
QtylE = QtylEngine QtylE = QtylMotor

=*E
m-T-z;y-gs a406 99.06 - ESO
 I"AN
BSW
'<
i
Plate
Page I(2) Connection Pipe 51206-02H
 ZJMD - B&W

51206-02H Connection Pipe Plate

Page 2 (2)

Item Item
no Qty Designation Benaevnelse no Qty Designation Benavnelse

014 1IE O-ring O-ring

051 41E Screw Skrue

217 11 Loctite Loctite

229 11E Connecting pipe Forbindelsesr~r

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs5 side 500.50.
= Only available as part of a spare parts kit. = Kun tilgzngelig som en del af et reservedelss.zd
- QtylE = QtylEngine QtylE = QtylMotor
Qtyll = Qtyllndividual Qtyll = Qtyllndividuelt

=-
--- - ---
==E=-=

=E~-w-?-G~~s
0406 99.17 - ESO
 i'MAN 'is
ZJMD- B&W i. B&W t

Plate
Page 1 (2) Charge Air Pipes

02.36- ESO 0406 -----

----
m ----v
- ---
p

- ---
-- -
-
-
p

GENERATING SETS
 Plate
51230-03H Charge Air Pipes Page 2 (2)

Item
No Qty Designation Benavnelse Qty Designation Benavnelse

015 I 1 l/E Flange Flange

302 l Screw, 5-6 cyl.
7 cyl. 1000 rpm
Skrue, 5-6 cyl.
7 cyl. 1000 rpm
Seal ring Tztningsring
5 cyl. engine 5 cyl. motor 326 Covering sheet Dzkplade
6 cyl. engine 6 cyl. motor
7 cyl. engine 7 cyl. motor 338 Screw Skrue
8 cyl. engine 8 cyl. motor
9 cyl. engine 9 cyl. motor 483 Screw Skrue

039 1 2/E ) Screw Skrue

495 1 Screw Skrue

Lock washer Liseskive 505 Screw Skrue

5 cyl. engine 5 cyl. motor
6 cyl. engine 6 cyl. motor
7 cyl. engine 7 cyl. motor
8 cyl. engine 8 cyl. motor
9 cyl. engine 9 cyl. motor

Intermediate piece Mellemstykke

OM I 1 l/C Safety clamp Sikkerhedsring

l
Pipe piece Rsrstykke

Screw Skrue

Pipe piece Rsrstykke

Screw Skrue

Flange, 5-6 cyl. Flange. 5-6 cyl.

7 cyl. 1000 rpm 7 cyl. 1000 rpm

Flange, 8-9 cyl. Flange. 8-9 cyl.

7 cyl, i200rpm 7 cyl. 1200rpm

Screw Skrue

Screw Skrue

Screw Skrue

Compensator Kompensator

Diffuser Diffusor

255 I I Flange, 5-6 cyl.

7 cyl. 1000 rpm
Flange, 5-6 cyl.
7 cyl. l000 rpm

267 l I
lE
Plate, 8 9 cyl.
7 cyl. 12OOrpm

Screw, 8-9 cyl.

Plade. 8-9 cyl.
7 cyl. 1200rpm

Skrue, 8-9 cyl.

7 cyl. 1200rpm 7 cyl. 1200rpm

When ordering spare parts, see also page 500.50. Ved bestilling af rese~edele,se o g s i side 500.50.
= Only available as part of a spare parts kit. = Kun tilgzngelig som en del af et reseNedelss32t.
Qty/E = QtylEngine Qty/E = QtyIMotor
Qty.lC = QtyJCylinder Qty./C = Qty./Cylinder

02.36 - ESO
 Compressed Air System

--
!compressed air system

I A I filter
~ $83-01.22 (01H) iI
1

/Overhaul, test and inspect~onof air starter 513-06.30 (03H) l1

l
;Overhaul, test and inspect~onof air starter 1513-01.30 (t26H) i
l
l
'Emergency starting valve sls-01.49 (02%) i
l
!Check of compressed air ~ i p i n ssystem 513-31.90 ( Q 3 H ) I

iAir starter 5 1329-08i;

l . -
- I
l
! A I starter
~ 5:3~5-143 l

/ A I starter
~
--
(Supplement foi p e x 5 1 3 0 0 - l e H 1 513QS-i5f-f Il

1 ' ~ a.i n
stop
-
valve
. _
'51315-O2M i
1 - - - .- -
, - -1
/Air f~lter
--- - -
15132%-EiZH . . - - . - - - - i
I
-

:Turning gear wrth artachment 151325-02~

- - --- -- --.
- - - --.-- . _ ._ - - _ _ - _ / - . - i
i 7 1
loverspeed stop valve i51327-0%~
' .- -- I
7
-
- I
/Arrangement of j e t system
IStart~ngair receiver
- -- --
.- -

.
.- "

-
52330-62H
151335-cm- --
." -

. . -.
l
l
 !M A N 'r
F B&W:

Description 513.01
Page 1 (2) Compressed Air System Edition 07H

Reduction valve

' Mair, starting valve:

!
- I Emergency sta6 valve
I
I
lI
,__F_____--___--------
' P.i: starter incl. main valve
' A and reduction valve

Compressed air to TC,

and overspeed stop

Charcinq
- - air inlet.
(see co7Sus:ion air d~agramj

Fig. l Diagram for compressed air sysfem.

General Control System

The compressed air system on the engineconsists of
a starting system, starting control system and safety
system. Further, the system supplies air to the jet
system.
The compressed air is supplied from the starting air
receivers (16-30 bar) through a reductionstation,from
where compressed air is supplied to the engine.
The air starter is activated electrically with a pneu-
matic 312-way solenoid valve. The valve can be
activated manually from the starting box on the
engine, and it can be arranged for remote control,
manual or automatic.

Toavoid dirt particlesin the internal system, astrainer

-
N
7

ro is mounted in the inlet line to the engine.

9
F
U,
0
N
Ln

I
Starting S y s t e m
n
9
m
N
0 The engine is started by rneansof a built-on airstarter,
m
O which is a turbine motor with safety clutch and drive
shaft with pinion. Further, there is a main starting
valve.

00.14 - ES1 0406 --

-- F
GENEFAlWC SETS
-
 51 3.01 Description
Edition Q ~ H
Compressed Air System Page 2 (2)

For remote activation the starting coil is connected so Pneumatic S t a r t Sequence

that every starting signal to the starting coil goes
through the safe start function which is connected to When the starting valve is opened, airw~llbe supplied
the basemodule mounted on the engine. to the drive shaft housing of the air starter.

Further, the starting valvealso acts asan emergency The air supply will - by activating a piston - bring the
starting valve which makes it possible to activate the drive pinion intoengagement with the gear rim on the
air starter manually in case of power failure. engine flywheel.

Safety System
As standard the engine is equipped with a pneumati-
cally/mechanically stop cylinder, which starts to
operate if the safety system is activated. The system
is activated electrically.
Airsupply must not be interrupted when the engine is
running.
When the pinion is fully engaged, the pilot air will flow
to, and open the main starting valve, whereby air will
be led to the air starter, which will start to turn the
engine.
When the rpm exceeds approx. 158, at which firing
has taken place, thestarting valve is closed whereby
the air starter is disengaged.
Optionals

Besides the standardcomponents! the following stan-

dard optional can be built-on:

- Main valve, inlet engine.

-
= ==-L=.=
CS-TIUG
S-==
L _ _
=
SETS
 ZJMD -
Working Card
Page 1 (2) Air Filter l 51Edition
3-01m2101 H l

l
Safety prezeutionr Spesiai
i i
Stopped engine / Plate no Item no Note j
1 i
ll
Shut-off starting air
Shut-off cooling water l
Shut-off fuel oil l
Shut-off nozzle cooling oil i 1
Stopped ub. oil circul. !
II lr
1 E Press Blocking - Reset
l
1
j
Ee-.n"*nL.
-3t.1 lrclC2D
l
i
i Hand tc.w[s
l

3
l
!
I
1 !
l 1
1 Cleaning andlor maintenance of air filter. f 1
l /
i i

1
l

l
1
t
Stading position
i
l
i
i
l
i

l
I
l
I
l
l
i
ii
I
l
We!zted procedure

1 I
i
1
j
i
l
I

l
i
l
N
7

m
9
Manpower 1 Replacement and pa:tS
.
W
m
0
In
In
N Working time : hours Plate no Item no Qtyl
I Capacity man
a
4
m
N
a
0 Data
0

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45) 1

02.46 - ESO 0406

=
GE-TING
=E=&
-
s ~ r s
513-01.21
Edition 01H
15 Depressurize unit.
2) Remove bowl and bowl guard assembly by
turning counter-clockwise.
3) Inspect bowl for damage seals and replace, if
nessesary.
4 ) If bowl becomes dirty clean it by wiping the
bowl with a soft dry cloth or mild detergent.
5) Before returning to service, insure that all
seals have been reinstalled or replaced.
6) Reinstall bowl and bowl guard assembl y and
rotate bowl guard clockwise to securely lock in
place. Align arrow on bowl guard with arrow on filter
body.
Fig l Air Filter
Air Filter Working Card
Page 2 (2)
Ta replace filter e i e ~ ~ ~ i t :
7 ) Depressurize unit
E) Remove bowl and bowl assembly by turning
counter-clockwise.
9) Unscrew baffle by turning counter-clockwise.
$8) Remove filter element and discard.
?'lf Install new filter element and reassemble in
reverse order.
12j Before returning to service, insure that all
seals have been reinstalled or replaced.
'3) Reinstall bowl and bowl guard assembly and
I'
rotate bowl guard clockwise to securely lock in
place. Align arrow on bowl guard with arrow on filter
body.
02.46 - ESO
 Work~ngCard
Overhaul, Test and Inspection of Air Starter
51 3-01.30
Page 1 (4) Edition 03H

Safety p r e c a u t i o n s Special tools

B Stopped engine Plate No ltem No Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Stopped lub. oil circul.
E Press Blocking - Reset

Description Hand t o o l s

Check of air starter 1 flex. male key 4 mm

Disassembly, overhaul and assembly of the air
starter.

Starting p o s i t i o n

All connections to the air starter have been remo-

ved, and air starter is removed.

Related p r o c e d u r e

Manpower Replacement and wearing p a r t s

Working time : 2 hours Plate No ltem No Qtyl

Capacity 1 man
51309 278 l (spare part kit)

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.48 - ESO 0406 -

--
---
F
m----
=
-- -
--=
--
S

CBUERATNG SETS
 ZJMD - 6&W

513-01.30 Overhaul, Test and Inspection of Air Starter

Working Card
Page 2 (4)
Edition 03H

It is not nessesary to disassemble the air starter for

inspection, only if overhaul is necessary due to worn
parts.

lnspection

1) Check the drive pinion.

Note: This should be shiny and no special wear must

appear on both side of the teeth.

2) Check with a torque spannerthe tighten ofthe

drive pinion screw. This must be 54-61 Nrn.

3) Check the flange cover screw are tighten to4-

5 Nrn.

1 10 Gasket for housing cover 16 Drive housing seal

11 Housing cover 17 Inlet flange, complete

I
-
Fig 7 Air starter

98.48 - ESO
 ,.-.

hGh
fl-T"?
.-+"-&&!, , : *

L- 'C:

ZJMD -
Working Card 513-01.30
Page 3 (4) Overhaul, Test and Inspection of Air Starter Edition 03H

Disassembly
Always wear eye protection when performing any
maintenance on this air starter.
Always turn off the air supply and disconnect the air
supply before installing, removing or adjusting any
accessoryon this airstarter or before performing any
maintenance on this air starter.
l) Do not disassemble the air starter any further
than necessary to replace worn parts.
2) When grasping a part in a vise, always use
leather-covered or copper-covered vise jaws
to protect the surface of the part and help
prevent distortion. This is paritcularly true of
threaded members.
3) D o not remove any part which is a press fit in
oron a subassembly unless the removal ofthat
part is necessary for replacement or repairs.
11) Remove the drive housing seal (16) from the
flange cover.
12) Turn the air starter over and secure it vertically
in a fixture.
Note: Use care when removing the housing cover
bolts (12) holding the housing cover ( I l ) to the air
starter. The liner (9) is spring loaded and will pro-
trude approximately one inch beyong the housing
when released.
13) To remove the housing cover, slowly loosen
the four housing cover bolts while holding the
housing cover in place.
14) Slide the liner assembly out of the housing.
15) Remove the return spring (8).
Assembly

4) Always have a complete set of seals and o-
rings on hand before starting any overhaul of
the air starter. Never reuse old seals or gas-
kets.
5) When disassembling, always mark adjacent
parts so the members can be located in the
same relative position when the air starter is
reassembled.
6) Neverwash the linerassembly (9) in a solvent.
16) Always press on the inner ring of a ball-type
bearing when installing the bearing on a shaft.
17) Always press on the outer ring of a ball-type
bearing when pressing the bearing into a bear-
ing recess.
18) Whenever grasping an air starter or part in a
vise, always use leather-covered or copper-
covered vise jaws. Take extra care with treaded
parts or housings.

Disassembly of the Air Starter Assembly of the Air Starter

7) Remove the drive pinion screw (l) from the 19) Place the housing (13), front end down so that
drive shaft and remove the drive pinion (2). the retum spring (8) can be placed into the
housing.
8) Remove the six flange cap screws (3) from the
.-
N

a5
housing (13). 20) Slide the liner assembly (9) into the housing.
Orient the liner so that the notch aligns cor-
2m 9) Remove the flange cover (4) and flange (5) rectly with the housing inlet port and liner air
S
In simultaneously by pulling up on the flange. inlet port aligns with the housing inlet port.
a
In
z
n
Attach housing cover gasket (10) to housing
o 10) Remove the front drive shaft bearing (15) from cover.
m
N
0
(0 the flange cover.
0

98.48 - ESO 0406 - ----

--
-- - - --
=--E
--m--
F=-

GENERATWC SETS
-=-
 ZJMD - B&W

513-01.30 Working Card

Edition 03H
Overhaul, Test and Inspection of Air Starter Page 4 (4)

21) Attach the housing cover ( I l ) to the housing 29) Attach the drive pinion (2) to the drive shaft
with just one housing cover bolt (12). Engage using the drive pinion screw (1) and Locktite,
only a few threads so that the housing cover tighten to 40-45 ft-lb (54-61 Nm) torque, fig 1.
can be easily rotated.

22) While pushing thelinerassembly down against Test and Inspection

the return spring, rotate the housing coverover
the liner to hold it down. Warning ! When 6 bar air pressure is applied to the
air starter, the drive pinion will be rotating at 2,800
23) Tighten the housing cover cap screws to5-6 ft- rpm and drive shaft and drive pinion will move
Ib (6.7-8 Nm) torque. forward 30-32 mm. Keep face and hands awayfrom
rotating drive pinion.
24) Press the drive housing seal (16) into the
flange cover (4) with the sealing lip pointed 30) Orientation: Mounting flange must be ori-
down. ented per the customer's order or engineering
drawing. If orientation is not specified by cus-
25) Press the front drive shaft bearing (15) into the tomer, standard orientation will be supplied.
flange cover.
31) Free speed (all models): Install air starter on
26) Fit the flange (5) onto the flange cover so that a test fixture. Apply 6 bar to the air starter
the counterbore of the flange slides over the motor. Minimum free speed is 2,800 rpm.
shoulder of the flange cover correctly.
32) Confirm overrunning o f clutch: Turn the
27) Carefully slide this assembly over the drive drive pinion by hand in the direction of rotation.
shaft. Be careful not to tear the seal lip. Orient The clutch should ratchet smoothly.
the flange correctly.
33) Confirm drive rotation: Turn the drive pinion
28) Tighten the six flange cap screws (3) to 3-4 ft- by hand in the direction of rotation. The clutch
Ib (4-5.4 Nm) torque. should ratchet smoothly.

=--
,
= ---=m=-- ---=
=E-
--=
98.48 - ESO
CEMUATNC SETS
 Working Card
Page 1 (2) Overhaul, Test and Inspection of Air Starter 1 513-01.30 1
Edition 06H

Safety precautions Special tools

1 @ Stopped engine 1

'
Plate No Item No Note
@ Shut-off starting air
O Shut-off cooling water
Shut-off fuel oil
Stopped lub. oil circul.
Press Blocking - Reset

Description Hand tools

Check of air starter

Disassembly, overhaul and assembly of the air
starter.

Starting position

All connectionsto the airstarter have been remo-

ved, and air starter is removed.

Related procedure

Manpower Replacement and wearing parts

Working time : 2 hours Plate No Item No Qv/

Capacity 1 man
51309 614 1
(set of seals, air starter)
Data
51309 615 1
Data for pressure and tolerance (Page 500.35) (repair kit, air starter)
Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

03.14 - ESO
 ZJMD
( 513-01.30 1
Edition 06H
Overhaul, Test and Inspection of Air Starter
Operation
Before putting into operation
- Check if the installation has been accom-
plished in accordance with our instructions.
- Check the adjustment of the auto-start device
(if installed), to ensure:
- the speed of the starter shaf? never ex-
ceeds the value of 3.500 rpm.
- the starter stops working, once the engine
hasattained a speed 1 to 1.5 times is
ignition speed.
- Check that the air receiver is charged and that
the flow valve is opened.
- Test for leaks and check that the control circuit
is not chocked.
- Check for correct meshing ofthe driving pinion
with the flywheel gear ring by means of several
short starter impulses.
- BSW
Working Card
Page 2 (2)
On putting into operation
In case of manual start, operate the push-button
valve for very short periods only.
Complete Overhaul
- Strip the starter and clean all lines and pipework.
- Check rotors and advance mechanism; clean
same and replace worn or rusted parts.
- Check the driving pinion for wear and replace
it if necessary.
- Revice all valves and replace joints.
Storage
When leaving ourworks, the starters contain antirust
oil to protect their inner parts. In spite o this, we must
recommended storage in a dry place.
03.14 - ESO
 $' MAN i
i S&W '

Working Card
Emergency Starting Valve 513-01.40
Page 1 (2) Edition 02H

Safety p r e c a u t i o n s Special tools

I H Stoppedenglne Plate No ltem No Note

H Shut-off start~ngair
Shut-off cooling water
Shut-off fuel 011
Stopped lub. oil circul.
Press Blocking - Reset

Descripf i o n Hand t o o l s

Lubricating, disassembly and reassembly of Small screwdriver

emergency starting valve in starting system.

Starting position

Related p r o c e d u r e

Manpower Replacement a n d w e a r i n g p a r t s

Working time : 1 hour Plate No Item No Qty.1

Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.45 - ESO
 513-01.40 Working Card
Edition 02H Emergency Starting Valve Page 2 (2)

Emergency Starting Valve

The emergency starting valve is placed on the tur-

bine starter and should be tested according to the
v
planned maintenance programme.

1) Switch the engine to "local" on the operating

box panel.

2) Push the emergency start button with a small

screwdriver, as shown in fig 1, until the engine
ignites.

3) Release the button. The button is springloaded

and will automatically return to the start posi-
tion.

l l

F I I~ Emergency starting valve.

--
---
e r-e
m ---p
--
- - --
-sss
0406 98.45 - ESO
CENERATNG SETS
 Working Card
Check of Compressed Air Piping System
51 3-01.90
Page 1 ( 2 ) Edition 03H

General

Safety precautions Special tools

Stopped engine Plate no Item no Note

a Shut-off starting air
O Shut-off cooling water
0 Shut-off fuel oil
U Shut-off nozzle cooling oil
Stopped lub. oil circul.
[? Press Blocking - Reset

Description Hand tools

Check of compressed air piping system Screwdriver.

Starting p o s i t i o n

I Compressed air connected to the engine,

Replacement a n d wearing p a r t s
Manpower
Plate no Item no Qty. /
Workingtime : 114 hour
Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

02.20 - ESO
513-01.90 Check of Compressed Air Piping System Working Card
Edition 03H Page 2 (2)

General

With Air Connected With Air Disconnected and Stopped Engine

1) Examine the piping system for leaks. 6) Move all valves and cocks in the piping
system. Lubricatevalve spindles with graphite
2) Retighten all bolts and nuts in the piping or similar.
system.
7) Connect the air supply and make a function
3) Drain the system for condensed water. This test of the emergency valve. See Descrip-
should be based on observations. tion 513.01.

4) Check flexible connections for leaks and

damages.

I t i s important that the flexible connections are free

from paint and grease and in healthy condition.

5) Check manometers.

02.20 - ESO
 Plate
Page I(2) Air Starter 51309-08H

Seen
from A
408

P\
All valves and fittings
has to be approved by
classification society.

- ----
- -----
- --
01.32 - ESO 0406 - -----
-- -
-
L

-
--
--
p
-
---
- -

CEUE?AT!NC SETS
- - -
 Plate
51 309-08H Air Starter Page 2 (2)

ltem
no 1 Qtv 1 Desianation Benawnelse
ltem 1
no Qty 1 / Designation Benzwnelse

11s
l
Drive pinion screw Tandhjulsskrue 3 9 /' 11s
1
Fittings Fittings

11s Drive pinion, Tandhjul, 350 / l/S j Reduction Reduktion

1 incl item 291 inkl. item 291 1 1
i 362 ( 11s i Ball valve Kuglehane
11s I Gasket for housing Pakning for
1 cover motorhusdzksel 374 ( 11s Fittings Fittings

1
I
l l
11s Front drive shaft Forreste 386 11s ;
l
Fittings F~tt~ngs
( bearing drivakselleje , 1

- 063 I 1 11s Drive housing seal Tztning for drivgear

408

421
l
l
' 11s
11s '
l
Solenoid valve 312

Nipple
Magnetventil 312

Nippel
Flange cap screw D~kselskruefor i
l
flange 433 11s Flange Flange

099 / 11s Flange cover Flangedzksel 470

l
11s
l
Fittings F~tlings

109 1 l i S ' Flange

l
Flaige 482 11s Fittings Fittings

I34 / 11s I Return spring Fjeder 494 11s r Filter F~lter

158 1 IIS Housingcover Motorhusd~ksel 565 115

l
Fittings Fittings

I
I

41s // Bolt for housing Bolt for motorhus- 577 11s Nipple (T) Nippel (T)

183 j 11s
i
I
cover

Housing
d~ksel

~o~orhus
589 ' 11s 1 Nipple Nippel

l
Vent plug Afluftningsskrue
600 l!S Safety valve Sikkerhedsventil
Mounting boit Bolt for rnontenng

0-ring 0-ring
612 1 l / S I Pressure reduction TrykreduMions-
ventil
1 1 valve
I

Air starter corn- Starternotor kom- 11s Spare parts kit for Reservedelskit for
plete, ST40O and plet, ST400 og : ST400, incl. item ST400, inkl. item
RRIOO RRlOO ( 014,038,051, 063, 014, 038,051, 063,
087,217,230 (not 087, 21 7,230 (ikke
I screw Skrue l shown on the front vist p i forsiden)
l

Washer Skive l

Spare parts kit for Reservedelskit for

Spare parts kit f o r Reservedelskit for item 494, consisting item 494, indeholder
valve RRIOO ventil RRlOO of element, o-ring element. c-ring

Shaft collar Stattering Spare parts kit for Reservedelskit for

item 325, consisting item 325, indeholder
Fittings Fittings of element, gasket element, pakning

Gasket Pakning

325 / ?/S / Strainer, complete Vandsi, kornplet

Fittings Fittings

When ordering spare parts, see also page 500.50. Ved bestilling af reservedeie, se ogsh side 500.50
= Only available as part o f a spare parts kit. = Kun tilg~ngeligsorn en del af et reservedelss~t
-.- QtylE = QtylEngine QtyIE = QtyiMotor
QtyIS = QtylAir starter Qry/S = QtyIStarlemotor

01.32 - ESO
 ZJMD - B&W

I Plate
Page 1 (2)
l Air Starter 1 51309-14H 1

All valves and fittings

has to be approved by
classification society.

616 A

For details see plate 51309-15H

03.14 - ESO 0406

-=
--- ----
=
::
E-EPIY
; =
P---

GENERATINZ SETS
 ZJMD -
Plate
151309-14H Air Starter Page 2 (2)

'Fom 1 ~ t yDesignation Benavnelse Benavnelse

Flange Flange Skzrering

Screw Skrue Skive

Distributor block Fordelerblok Forskruning

0-ring

Screw

Washer
0-ring

Skrue

Skive
235

616

617
/
1
21s

11s

11s
11 Male connector

Solenoid valve

Filter i n ~ e i i
Forskruning

Magnetventil

Filterindsats

Nut M~trik
1 l
i

Threaded pin Gevindtap

Solenoid valve Magnetventil

Elbow male Vinkelforskruning

connector

Connecting tube Forbindelsesr~r

Swivel connector Forskruning

0-ring 0-ring

11s Male connector Forskruning

21s Elbow union Vinkelforskruning

11s Strainer Filter

11s Holder Holder

11s Protective hood Beskyttelsessk~rm

21s Screw Skrue

11s Cap nut Daekselrnertrik

11s Bracket Konsol

21s Nut Motrik

11s Spacer plate Afstandsplade

215 Cap nut Daekselrnotrik

215 Washer Skive

11s Screw plug Propskrue

11s Male connector Forskruning

llS Elbow union Vinkelforskruning

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs5 side 500.50
= Only available as part o f a spare parts kit. = Kun tilgengelig som en del af et reservedelss~t.
QtyIE = QtyIEngine QtyIE = QtyIMotor
QtyIS = QtyIAir starter QtyIS = QtyIStarternotor

I ===
EpM
--- -
c=--- 0406 03.14 - ESO
&-z'&T-zI;*E~s
 Plate
Page 1 ( 2 ) I Air Starter (Supplement for plate 51309-14H) 151309-15H 1

601

Tor U
6-8%

578
i-- 514 592

517 506 504 507 536 512 519 604 557

All valves and fittings

has to be approved by
classification society.

03.14-ESO 0406 -
GENERATING SETS
I Plate
Page 1 (2)
1 Main Stop Valve

029

All valves and fittings

has to be approved by
classification society.
 1 MAN ;
;' E & W I

51315-02H Main Stop Valve Plate

Page 2 (2)

'E1 -signation

IN Gland flange
Benavnelse

Ters
IF," Clty 1 Designation Benaevnelse

029 1 IN 1 Stem with disc Spindel rned skive

010 ( IN Gasket Pakning

042 )
l
1IE / Stop valve, complete Stopventil. kornplet

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsi side 500.50.
= Only available as part of a spare parts kit. = Kun tilgzengelig sorn en del af et resewedelsszt.
Qty.lE = Qty.lEngine. AntalIE = AntalIMotor.
Qty.lC = Qty.Nalve. AntalN = AntalNentil.

---- ---
-- - - --
-E-4
-v---
CDUERATYUC SETS
0406 99.03 - E 0 0
 Plate
Page I (2) Air Fifter 51321-02H

02.46 - ESO
 Plate
51 321 -02H Air Filter Page 2 (2)

ltem
No. Q t y I Designation Benzvnelse
ltem
No.
l
Qty.
l
Designation Benzvnelse

177 ( IIE ( Filter complete Filter komplet

Reparationss~t
(filter and 0-ring) (filter og 0-ring)

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsd side 500.50.
= Only available as part of a spare parts kit. = Kun tilg~ngeligsorn en del af et reservedelss~t.
Qty.lE = Qty.lEngine. AntallE = AntallMotor.

02.46 - ESO
 Plate
Page 1 (2) Turning Gear with Attachment 51325-02H

A All valves and fittings

has to be approved by
classification society.

99.03- ESO 0406

----=r --
--
m m----
- ---
m
CWERATNC SETS
 ZJMD - B&W

Plate
51325-02H T ~ ~ r n i nGear
g with Attachment Page 2 (2)

tom I Qty Designation Benavnelse Designation Benavnelse

Sleeve Bssning

1IE l Shaft Aksel

Pressure spring TryMjeder

Screw Skrue

Screw Skrue

1/E

1/E
i
j
Position swich

Flange
Position switch

Flange

Spur gear Cylindrisk tandhjul

1/E I Shaft, complete incl. Aksel, kornpletinki. item

/ item 0 2 3 , 0 3 5 , 0 7 2 , 0 8 4
025,035,072,064
l

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogss side 500.50.

L = Only available as part o f a spare parts kit. = Kun tilg~ngeligsom en del af et rese~edelssaet.
QtylE = QtyIEngine. QtylE = Qty/Motor.

99.03 - ESO
 r
Plate
Page 1 (2) Overspeed Stop Valve 51 327-01H

General

m
0
cWn
A All valves and fittings
has to be approved by
classification society.

99.03- ESO
51327-01H Overspeed Stop Valve Plate
Page 2 (2)

General

Item
No 1
i
Qty
!
/ Designation Benavnelse Designation Benavnelse

Solenoid valve 312, Magnetvent113!2,

complete komplet

1/E 1 Coil
l
l
!
l
l!
I
I

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs* side 500.50
= Only available as part of a spare parts kit. = Kun tilgzngelig sorn en del af et reservedelsszt
QtylE = QtylEngine. QtyIE = QtyIMotor.

99.03 - ESO
 ZJMD - B8rW

Plate
Page 1 (2) Arrangement of J e t System 51330-02H

A All valves and fittings

has to be approved by
classification society.

...--L:
L
l,----.-.

I
:
\
..
.:
,
-.--

:
j
l

:, I
*;.
L.
'r-T--;'.
$-:-cl R
I
8

--+ 1
I

:
-.,
,

I I
I

I : :
<-L.-:
r
<

$5

- 1
....---,
.......-+
L =
.,
-----.
..L ..
>-

99.03- ESO
---
= --=-=.= ---=
-- ---p-

--a

0406
CENERATNG SErS
 Plate
51330-02H Arrangement of Jet System Page 2 (2)

Item
Q~Y Designation Benavnelse no
- -
l/E Pipe Ra r

1/E Pipe R0r

1/E Pipe Rar

5/E Pipe clamp R~rholder

l OlE Screw

2/E 1 Pipe clamp

Skrue
l
Straight male stud Ligeforskruning
coupling

Solenoid valve 212, Magnetvenfil212,

complete komplet

1 Straight coupling Ligeforskruning

Spole

Housing Hus

Screw Screw

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se o g s i side 500.50.
= Only available as part of a spare parts kit. = Kun tilgiengelig som en del af et reservedelssiet.
QtyIE = QtyIEngine Qty/E = QtylMotor

99.03 - ESO
 MAN
z~~~-(eaw\
Plate
Page I(2) Starting Air Receiver 51335-01H

General

A All valves and fittings

has to be approved by
classification society.
 Plate
51335-01 H Starting Air Receiver Page 2 (2)

General
Item Item
No Qty Designation Benzvnelse No Qty l Designation Benzevnelse

016 1/E Starting air receiver, Starteluftreceiver,

complete kornplet
1
028 l/E Pressure gauge valve Manorneterventil

041 IIE Safetyvaive Sikkerhedsventil i

053 l/E Starting valve Starteventil
I l
065 1IE Backfilling valve Pifyldningsventil 1l !
077 1/E Air relief valve Afluftningsventil 1 I
089 1/E Auxiliary valve Hj~lpeventil ' i
l
090 l/E Drain valve Drznventil

l
1 i
! :
l

I
l
1
~
!
! l

!i
I
l
!
l

When ordering spare parts, see also page 500.50. Ved bestilling af resewedele, se o g s i side 500.50.
= Only available as part of a spare parts kit. = Kun tilg~ngeligsom en del af et resewedelss~t.
QtylE = QtylEngine. QtyE = QtylMotor.
 Fuel Oil System

]Internal fuel oil system j

/Dismounting / mounting o f fuel injection pump

1514-~1.05(05H)
j(~'0range) I

i is mount in^ / mounting of fuel injection pump i

/514.-a1.05 (CI7R)
I(vioodward)

I ~ ~ s a s s e m b/l yassembly and repalr of fuel l n j e c t ~ o n '

i
;pump (Woodward)
1514-a1.06
(05H)

jD~sassembly/ assembly and repair of fuel injection '514-01.06(195H)

/pump (L'Oranqe)
-
i
!Fuel injection valve (L'Orange) j5H4-01.16 (88H) i
r
/Fuel rnjecrron valve (Woodward) j514-03.10(09H) I
i
/check of fuel oil ~ i ~ i svstern
n q ki14-0%.90(04H)

t
]Fuel inject~onp u m p (Woodward) 51401-04W c
l

]Fuel injection p u m p (L'Orange) 514Dl-07H I

l
- - -
!
\Fuel ~ n j e c t i o nvalve (Woodward) '51402-1l~ l
i
)Fuel i n j e c t ~ o nvalve (L'Orange) ,54402-12H ii
I- --- - -. - . - - - I

l
l ~ u e Injection
l pipe (Woodward) 51404-06H I
- - -
i
- .
. -.
. . .- -
- -l
;Fuel Injection pipe (L'Orange) '51404-07H !
I1
iSafety filter 4 - 151415-01H
/Fuel oil arrangement '51430-02H I
I

IFuel 011arrangement !51436-03H l

j
- - . - - -
I
Fuel Injection p u m p connections (L'Orange) 51435-03H I
-- - - - l

j ~ u e injection
l p u m p connections (Woodward) i51435-04~
1
 ZJMD - B&W

Description 514.01
Page 1(2) Internal Fuel Oil System Edition 02H

Fuel Oil System
The built-on fuel oil system consists of inlet pipes for
fuel oil, mechanical fuel pump units, high-pressure
pipes as well as return pipes for fuel oil.
Waste oil and fuel oil leakages are led to a leakage
alarm which is heated by means of the inlet fuel oil.
Fuel Injection System
The fuel injection valve is located in a valve sleeve in
the centre of the cylinder head. The opening of the
valve is controlled by the fuel oil pressure, and the
valve is closed by a spring.
The high pressure pipe which is led through a bore in
the cylinder head is surrounded by a shielding tube.
'The shielding tube also acts as a drain channel in
order to ensure any leakage from the fuel valve and
the high pressure pipe will be drained off.

The engine is provided with one fuel injection pump The complete injection equipment including injection
unit, an injection valve, and a high pressure pipe for pumps and high pressure pipes is well enclosed
each cylinder. behind removable covers.

The injection pump unit is mounted on the engine

frame. The pump unit consists of a pump housing
embracing a roller guide, a centrally placed pump
barrel and a plunger. The pump is activated by the
fuel cam, and the volume injected is controlled by
turning the plunger.

98.41 - ESO
514.01 Internal Fuel Oil System
Descr~pbon
Page 2 (2)
Edltion 02H

Running-in Filter

The running-in filter has a fineness of 50 mm and is

placed In the fuel inlet lrne as an integrated part ofthe
fuel oil leak~ngalarm box. Its function is to remove
impurit~esIn thefuel pipe between safety filter and the
englne In the running-~nperiod.

Note: The filter must be removed beforeship delivery

or before handling overto the customer.

It is adviced to install the filter evely time the extern

fuel pipe system has been dismantled, but ~t is
imporfanfto remove the filter again when the extern
fuel oil system is considered to be clean for any
impurities.

0406 98.41 - ESO

 k,+y:mr
-":....J i
>, : .*: ..
P';MAN'i *\l

ZJMD - =&W =&W $

Working Card DismountinglMounting of 514-01.05

Page I(3) Fuel Injection Pump (L'Orange) - Edition O ~H

Safety precautions , Special t o o l s

Stopped engrne Plate no Item no Note

Shut-off starting alr
Shut-off coolrng water
Shut-off fuel oil
Stopped lub oil crrcul
B Press Blocking - Reset

Description Hand t o o l s

Dismounting/mounting of fuel injection pump. Open-end spanner, 36 mm

Unbraco top and ratchet, 10 mm
Plier for lock ring, outer
Unbraco top, 8 mm
Torque wrench
Tools ior cleaning.
Starting p o s i t i o n Clean kerosene or gas oil.
Antiseizure prodilct.
Cover for fuel injection pump has been (Copaslip, Molykote GN Plus or similar)
dismounted.

Related procedure

Manpower R e p l a c e m e n t and w e a r i n g p a r t s

Working time : 2 hours Plate no Item no Qty I

Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

01.08 - ESO
 51 4-01.05 DismountinglMounting of Working Card
Edition O ~ H Fuel Injection Pump (L'Orange) Page 2 (3)

Dismounting of Fuel lnjection Pump

Step l
Dismounting of fuel injection pipe.

l) Unscrew the sleeve piece (1).

2) Kemove the high pressure pipe.

Step 2 t
e
n n

Fig I Dismounfing of fuel injection pipe.

Dismounting of Fuel and Drain Pipes

4) The lock ring (l),

seefg2must be shifted into L l
the groove in the center of the pipe. Fig2 Dismounting offueland drain pipes.

5) Push the fuel and drain pipes into the adjacent

pump until the injection pump is free, see fig2.
turer to a uniform delivery quantity of 75% by means
of a pointer. The pointer position for the adjustment
Removal of Fuel lnjection Pump value, the "adjustment point", is a 18 mm and can be
read from the scale on the control rack.
6) Separate the spring loaded lever from the
regulating rod on the fuel injection pump. 8) Attach the injection pump to the engine frame,
tighten the 5 screws with a torque, according
7 ) Remove the screws in the bottom flange and to description 500.40.
take the fuel injection pump away.
9) Reconnect the regulating rod to the spring a
loaded lever. r
m
0
Mounting of Fuel lnjection Pump
d
S
ln
New pumps: Remove preserving agents. Assembly of the Pressure Pipe N
ln

F
R
-
The injection pumps are adjusted by the manufac- Renew O-ring (pos 2, fig. 4), and coat the high-
10) 4D
pressure connecting thredsat the pump and at g
the pressure piece including the O-rings.

-
= - -- -
E
r =c=
-;
L =
-
-
=
-
-
=
CENEI+XTNG SETS
01-08 - ESO
r

Working Card DismountinglMounting of 514-01.05

Page 3 (3)
Fuel Injection Pump (L'Orange) Edition 06H

I'l) Screw the pressure pipe manually to the pres-
sure piece.
12) The correct positioning of the sealing cone
from the pressure pipe has to be checked. The
sealing cone must be completely ummersed
into the pressure nozzle of the injection pump
(approx. 3.6 mm). The sleeve nut has to be
screwed manually to the pressure socket of
the injection pump.
13) Tighten the sleeve nut at the pressure piece
with 65 + 5 Nrn.
Mounting of Fuel and Drain Pipes
15) Check the fuel and leakage pipes, they must
not have any sharp bores on the outer circum-
ference, the inner circumference must b e free
of any residuals.
16) Rub the O-rings in the injection pump with
paste for lip-type packing.
17) Mount the pipes opposite order of dismantling
point 4-5.

14) Tighten the sleeve nutatthe connecting socket

of the pump with 65 + 5 Nm.
 ZJMD - B&W

Worklng Card DismountinglMounting of 514-01.05

Page 1 (3) Fuel Injection Pump (Woodward) Edition O ~ H

Safety p r e c a u t i o n s Special t o o l s

I Stopped engine Plate no Itern no Note

1 E Shut-off starting alr
Shut-off cooling water
Shut-off fuel oil
B Stopped lub. oil circul
Press Blocking - Reset

Description Hand t o o l s

Disrnountinglrnounting of fuel injection pump. Open-end spanrer, 36 mm

Unbraco top and ratchet, 10 mm
Plier for lock ring, outer
Unbraco top, 8 mm
Torque wrench
Tools for cleaning.
S t a r t i n g position Clean kerosene or gas oil.
Antiseizure product.
Cover for fuel injection pump has been (Copaslip, Molykote GN Plus or similar)
dismounted.

Related p r o c e d u r e

Manpower Replacement and w e a r i n g p a r t s

Workirlg time : 2 hours Plate no Item no Qty :

Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

01.05 - ESO 0406 ----

g
-----
---
==E!%& %=S---
CWERE;TP\IG SETS
 514-01.05 Dismounting/Mounting of Working Card
Editron O ~ H Fuel llljection Pump (Woodward) Page 2 (3)

Dismounting of Fuel lnjection Pump

Step 1
Dismounting of fuel injection pipe.

l ) Unscrew the sleeve piece (1).

2) Remove the high pressure pipe

l 1 Sleeve piece .

Step 2
t

i I

Fig I Dismounting offuelinjedion pipe.

Dismounting of Fuel and Drain Pipes

4) The lock ring ( l ) ,see fig2 must be shifted into

the groove in the center of 'the pipe. Fig 2 Disrnounfing of fuel and drain pipes

5) Push the fuel and drain pipes into the adjacent

pump until the injection pump is free, see fig2.
8) Attach the injection pump to the engine frame,
tighten the 5 screws with a torque, according
Removal of Fuel lnjection Pump to description 500.40.

6) Separate the spring loaded lever from the 9) Reconnect the regulating rod to the spring
regulating rod on the fuel injection pump. loaded lever.

7) Remove the screws in the bottom flange and

take the fuel injection pump away. Assembly of the Pressure Pipe

I 0) Renew 0-ring (pos2, fig. 4), and coat the high- $

Mounting of Fuel Injection Pump pressure connectingthreds at the pump and at
the pressure piece including the 0-rings. ?
0

New pumps: Remove preserving agents: 3

m
1I ) Screw the pressure pipe manually to the pres- g9
The injection pumps are adjusted by the manufac- sure piece. m
N
0
! turerto a uniform delivery quantity of 75% by means m
a
of a pointer. The pointer position for the adjustment
value, the "adjustment point", is a 18 mm and can be
read from the scale on the control rack.

01.05 - ESO
Working Card DismountinglMounti~~g of 514-01.05
Page 3 (3)
Fuel Injection Pump (Woodward) Edition 07H

12) The correct positioning of the sealing cone
from the pressure pipe has to be checked. The
sealing cone must be completely umrnersed
into the pressure nozzle of the injection pump
(approx. 3.6 mm). The sleeve nut has to be
screwed manually to the pressure socket of
the injection pump.
13) Tighten the sleeve nut at the pressure piece
with 65 + 5 Nrn.
14) Tighten the sleeve nut at the connecting socket
of the pump with 65 + 5 Nm.
Mounting of Fuel and Drain Pipes
15) Check the fuel and leakage pipes, they must
not have any sharp bores on the outer circum-
ference, the inner circumference must be free
of any residuals.
16) Rub the 0-rings in the injection pump with
paste for lip-type packing.
17) Mount the pipes opposite order of dismantling
point 4-5.
 ZJMD - B&W
-
Working Card Disassemblylassembly and Repair of 514-01.06
Page I(5)
Fuel Injection P u m p (Woodward) Edition O ~ H

I Safety precautions
I
' Special tools

l Stopped engine
Shut-off starting air
Plate no Item no Note

Shut-off cooling water

Shut-off fuel oil
a Stopped lub. oil c~rcul.
Press Blockrng - Reset

Description Hand tools

Disassembly/assembly and repair offuel injection Adjustable spanner 12"
Pump Unbraco top and ratchet 5,8 mm
Torque wrench
Aluminium arbor
Tools for cleaning.
Clean kerosene or gas oil.
Antiseizure product.
Starting position (Copaslip, Molykote GN Plus or similar)

Dismounting of fuel injection pump 514-01.05

Related procedure
Mounting of fuel injection pump 514-01.05

Manpower Replacement and wearing parts

Working time : 2 hours Plate no Item no Qty 1

Capacity 1 man

Data

Data for pressure and tolerance(Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

01.OS- ESO
 ZJMD - B&W

51 4-01.06 Disassemblylassembly and Repair of Working Card

Edition 05H Fuel Injection Pump (Woodward) Page 2 (5)

If damages occur at the injection pump during the

warranty period the service of the manufacturer or of
a contracted workshop shall be utilized, otherwise
you lose your rights under the guarantee.

Note! It must be cared during the disassemblyof the

injection pump that the workplace is free of chips and
contaminations. It is recommended to clean all parts
with diesel fuel oil, and to place them on a non-
fuzzing cloth.

The complete injection pump must not be placed on

hard or metallic surfaces by the roller. Do not use the
extractable control rack as a handle!

The F o l l o w i n g G u i d e l i n e s s h a l l b e
Considered

3 Do not mix up parts of the pump element and

of the constant-pressure release valve.

3 High-pressure surfaces must be protected Barrel

1 Socket
against damage, and cleaned with clean Die- 2 Blocking screw Spring plate
sel fuel and a non-fuzzing cloth or paper when 3 Contro! rack Pump spring
they are installed again. 4 Pump casing Slicing block
5 Sealing ring Thms: piece
3 O-rings on demounted parts shall generally be 6 Cavitation screw Cylindrical screw
replaced by new O-rings before parts are Roller tappet
installed again. Roller tappet
Pressure valve spring
Pressure valve housing
=, Only original O-rings of the manufacturer shall
Stroke lirnlter
be used. Apply paste for lip-type sealings to
Plunger
the O-rings before installation.
Control sleeve
Countersunk screw
=, Cylindrical screws must be coated by graphite Thrust piece
paste on the bearing surfaceand on the thread; Roller
tighten them crosswise~andstep by step (in Roller pin
three steps of equal torque) to the required Holding screw
tightening torque. Cylindrical screw

=, The cylindricalscrewsshallbe loosened cross-

wise and step by step (in three steps of equal Fig. 1Fuel injection pump
torque), too.
2m
Caution! The holding screw (24), see fig 1 and the E x c h a n g e of Pressure Valve m
N

cylindrical screw (12) are provided with a TufLok bolt U

protection. The bolts can be re-used. If there is no Loosen the cylindrical screws (25), see fig 7'. 0
TufLok (blue medium in the thread) in the thread any
1) ..
CO
m
0

more a new screw must be used. 2) Remove the delivery socket ( l ) , the stroke
limiter ( l 7) and the pressure valve spring (15).

-
t
m
----
-- --- =--
_ V-
_ =
CENERATM SETS
0406 01.05 - ESO
 Working Card Disassemblylassembly and Repair of 514-01.06
Page 3 (5)
Fuel Injection Pump (Woodward) Edition 05H

3) Exchange the pressure valve (The pressure 7) Screw off the sliding block (10).
valve can be exchanged as a component
group only). 8) Loosen the springforce and demount the
installation device.
4) Assembly in reciprocal order.
Tightening torque 45 Nm. 9) Take off the roller (22) and the roller pin (23).

Caution! Installation of the pressure-valve housing
(16) with an aluminum arbor and a non-fuzzing cloth
to protect the high-pressure surface.
Disassembly of t h e Pump Element
10) Loosen the 2 nbs. cylindrical screws (12)
M5x14, and take off the roller tappet (13).
11) Pull out the thrust piece (11) with the plunger
(1B),aftewards the pump spring (g), the spring
plate (B), and control sleeve (19).

5) Loosen the 4 nbs, holding screws (24) M6x35, 12) Turn the injection pump vertically by 180 de-
see fig I. grees.

6) Press in the roller tappet (14) by means of the 13) Further disassembly as under "Exchange of
installation device, see fig 2. pressure valve".

14) Screw off the blocking screw (2).

Fuel injection pump 15) Carefully press outthe barrel (7) with an alumi-
num arbor.

Installation

16) Pump elements can be exchanged as compo-

nent groups only. (plunger and barrel).

Tooi 17) Insert the barrel (7), see fig 7 carefully into the
injection-pump casing (4) with an aluminum
arbor and a non-fuzzing cloth to protect the
high-pressuresurface, and screw in the block-
ing screw (2).Tightening torque 5 Nm.

\ Roller 18) Further assembly see under "Exchange of

pressure valve".

19) Turn the injection pump vertically by 180 de-

grees.

20) Install the control sleeve (19) - care for the

marking! - control sleeve (19) milled tooth,
control rack (3) groove around circumference.

21) The further assembly is carried in reciprocal

l 1 order of disassembly (driving pin ofthe plunger
Fig 2 Dismounting of roller tappet. in the direction ofthe slot ofthe control sleeve).
Tightening torque: (24) 10 Nm + tuflok, (10) 20
Nm, (12) tuflok.

01.05 - ESO
 514-01.06 Disassemblylassembly and Repair of Working Card
Edition O ~ H Fuel Injection Pump (Woodward) Page 4 (5)

22) Marking on the driving pin, installed towards Caution! Secure the countersunk screws (20) by
the boring of the control rack. Loctite 601 - tightening torque 4 Nm

If a pump element is exchanged it is recommended

to check the pre-stroke. Proceed as follows: Pump-element S t i c k i n g

The injection pump is assembled without pump In case a pump-element sticking has occurred, uti-
spring (9) and cavitation screws (6). lizetheservice ofthe manufactureror ofa contracted
workshop. If this is not possible the following proce-
The plunger (18) is fixed in the control boring by the dure is recommended:
measuring pin, see fig 3.
23) Loosen the holding screws (24) M6x35, see fig
The span between the measuring sleeve and the I.
roller is measured by a depth micrometer.
24) Remove the roller (22) with the roller pin (23).
Thedifference to the required dimension of 10 0.05 +
mm has to be newly adjusted by thethrust piece (ZI), 25) Attach the installation device, see fig 2 and
if necessary. locate it in such a way that it acts as a securing
element ofthe rollertappet which is underpre-
Ifthe pre-stroke is not correct, the rnaxfirirlg pressure tension by the spring.
of the mentioned cylinder will be wrong.
26) Remove the sliding block (10)
Ifthe pre-stroke is correct then reassembly the pump
with spring (9) and cavitation screws (6) and tighten 27) Turn the injection pump vertically by 180 de-
with correct torque acc. to description 500.40. grees.

28) further as under "Exchange of pressurevalve".

29) Hit down the plunger (18) by an aluminum

arbor and a hammer, in interaction with the
installation device, until the spring pre-tension
pin
has been overcome.

30j Demount the installation device.

31) Proceed as described under "Disassembly of

the pump-element"

32) Installation and check-up of the pre-stroke see

under "Installation".

Preservation m
y

Q
Measuring sleeve
The main functional components of each injection
:
m
pump supplied by the manufacturer has been pre- 2I
served during its check-up in the test stand. 04'
a5
N
0
P3 gero cut S 102 having a viscosity of 3.5 mm2/sec
"
a
at 20°C according to DIN 53015 is used as preser-
ving agent.
Fig 3 Check ofpre-stroke.

-
-=
S rr;
=
- 7
W
--
m----
GENERATKG SETS
- ---
m=
m 01.05 - ESO
 M A N '*
ZJMD - B&W
*

- B&W i

Working Card Disassemblylassembly and Repair of 514-01.06

Page 5 (5)
Fuel Injection P u m p (Woodward) Edition O ~ H

All external surfaces are primed.
The processed external surfaces are coated with
anti-rust grease or preserved with preserving oil
Castrol Rustilo DWX31 having a specific gravity of
820 kg/m3 at 15°C according to DIN 51757.
The suction chamber of the injection pump is filled
with preserving agent through the fuel discharge
boring, and closed.
By moving the plunger, the hollows are filled with
preserving agent.

This preservation is effective for 2 years. All external surfaces coated with anti-rust agent
must be preserved once more.

The control rack has to be moved in regular intervals

ofapprox. 3 months to avoid a sticking of the plunger.
If the injection pump has not been put into operation
within 2 years after its delivery a re-preservation has
to be carried out. For that purpose, a protective cap
must be removed from the fuel discharge (upper
connection) at the injection pump.

01 .OS - ESO
 Working Card Disassemblylassembly and Repair of 514-01.06
Page 1 (4)
Fuel Injection Pump (L'Orange) Edition06H

Safety p r e c a u t i o n s Special t o o l s

Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cool~ngwater
E Shut-off fuel oil
E Stopped lub. oil circul.
Press Blocking - Reset

Description Hand tools

I Disassemblylassembly and repair offuel injection Adjustable spanner 12"

Unbraco top and ratchet 5, 8, 10 mm
Plier for lockring, inner
Torque wrench
Aluminium arbor
Tools for cleaning.
Clean kerosene or gas oil.
Antiseizure product.
(Copaslip, Molykote GN Plus or similar)
Dismounting of fuel injection pump 514-01.05

Related procedure
Mounting of fuel injection pump 514-01.05

l Manpower

Working time : 2 hours

R e p l a c e m e n t and w e a r i n g p a r t s

Plate no Item no Qty 1

Capacity 1 man

Data for pressure and tolerance(Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

01.05 - ESO
 514-01.06 Disassemblylassembly and Repair of Working Card
Page 2 (4)
Edition 06H Fuel Injection Pump (L'Orange)

If damages occur at the injection pump during the

warranty period the servlce ofthe manufacturer or of
a contracted workshop shall be utilized, otherwise
you lose your rights under the guarantee.

Note! It must be cared during the disassembly of the

injection pump that the workplace is free of chips and
contaminations. It is recommended to clean all parts
with diesel fuel oil, and to place them on a non-
fuzzing cloth.

The complete injection pump must not be placed on

hard or metallicsurfaces by the roller. Do not use the
extractable control rack as a handle!

The Following Guidelines shall be

Considered

3 Do not mix up parts of the pump element and

of the constant-pressure release valve.

3 High-pressure surfaces must be protected

1 Connection socket Bavrei
against damage, and cleaned with clean Die- Sp-ing plate
2 Cylindrical screw
sel fuel and a non-fuzzing cloth or paper when Pump spring
3 Regulating rod
they are installed again. 4 Pump casing Guid~ngscrew
5 Sealing rinc Thrust piece
=, 0-rings on dernounted parts shall generally be 6 Cavitation screw Sh~m
replaced by new 0-rings before parts are Tapoet insert
installed again. Roiler tappet
- Pressure valve spring
=, Only original 0-rings of the manufacturer shall Valve spring
be used. Apply paste for lip-type sealings to Plunger (1.5-20 cSt)
Plunger (< 1.5 cSt)
the 0-rings before installation.
Regulating sleeve
Lockring
Cylindrical screws must be coated by graphite Guide pin
paste on the bearing surface and on the thread; Roller
tighten them crosswise and step by step (in Plug screw
three steps of equal torque) to the required
tightening torque.
l
3 The cylindrical screws shall be loosened cross-
wise and step by step (in three steps of equal Fig 1 Fuel injection pump.

torque), too.

2) Screw off the sliding block (10).

Disassembly of Fuel Pump
3) Loosen the spring force and demount the
l ) Press in the roller tappet (14) by means of the installation device.
installation device, see fig 2.

01.05 - ESO
 ZJMD - IS&W

Working Card Disassemblylassembly and Repair of 51 4-01.06

Page 3 (4)
Fuel Injection Pump (L'Orange) Edition O ~ H

4) Take out the tappet insert (13), roller tappet Installation

(14), roller (22), thrust piece (1 l ) , pump spring
(9) and plunger ( l 711 8).
Caution! Be sure not to damage the plunger.
5) If necessary remove the lockring (20), guide
pin (21) and take out the regulating rod (3) as
well as the plug screw (23) in the opposite end
of the regulating rod (3).
6) Loosen the4 cylindrical screws (2) and remove
the connection socket (1) and barrel (7).
Pressurevalve is included in connection socket
( l ) and can be exchanged as a component
group only.
7) Carefully press out the barrel (7) with an alumi-
num arbor.
Fuel injection pump
8) Pump elements can be exchanged as compo-
nent groups only. (plunger and barrel).
9) Insert the barrel (7): see fig.I carefully into the
injection-pump casing (4) with an aluminum
arbor and a non-fuzzing cloth to protect the
high-pressure surface.
10) Mount the connection socket tighten the 4
cylindrical screws. Tighten torque 40 Nm.
11) Turn the injection pump vertically by 180 de-
grees.
12) Install the control sleeve (19) - care for the
marking!
13) The further assembly is carried in reciprocal
order of disassembly (driving pin ofthe plunger
in the direction of the slot of the control sleeve).
Guiding screw has to be mounted with loctite
0577.

14) Marking on the driving pin, installed towards

the boring of the control rack.

Tool

Roller

-
Fig 2 Dismounting of roller tappet.

01.05 - ESO
514-01.06 Disassemblylassembly and Repair of
Edibon 06H Fuel Injection Pump (L'Orange)
If a pump element is exchanged it is recommended
to check the pre-stroke. Proceed as follows:
The injection pump is assembled without pump
spring (9) and cavitation screws (6).
The plunger (18) is fixed in the control boring by the
measuring pin, see fig.3.
The span between the measuring sleeve and the
roller is measured by a depth micrometer.
+
The difference to the required dimension of 10 0.05
m m has to be newly adjusted by the thrust piece (21),
if necessary.
If the prestroke is not correct, the maxfiring pressure
of the mentioned cylinder will be wrong.
lfthe pre-stroke is correctthen reassembly the pump
with spring (9) and cavitation screws (6) and tighten
with correct torque acc. to description 500.40.
Caution! Secure the guiding screws (10) by Loctite
0577.
Fig 3 Check of pre-stroke.
Worktng Card
Page 4 (4)
Preservation
The main functional components of each injection
pump supplied by the manufacturer has been pre-
served during its check-up in the test stand.
P3 gero cut S 102 having a viscosity of 3.5 mm21sec
at 20°C according to DIN 53015 is used as preser-
ving agent.
All external surfaces are primed.
The processed external surfaces are coated with
anti-rust grease or preserved with preserving oil
Castrol Rustilo DWX31 having a specific gravity of
820 kg/m3 at 15°C according to DIN 51757.
This preservation is effective for 2 years.
If the injection pump has not been put into operation
within 2 years after its delivery a re-preservation has
to be carried out. For that purpose, a protective cap
must be removed from the fuel discharge (upper
connection) at the injection pump.
The suction chamber of the injection pump is filled
with preserving agent through the fuel discharge
boring, and closed.
By moving the plunger, the hollows are filled with
preserving agent.
All external surfaces coated with anti-rust agent
must be preserved once more.
The control rack hasto be moved in regular intervals
of approx. 3 months toavoid a sticking of the plunger.
01.05 - ESO
 -...,
<-*"&"Zi.
,,

P'p:'- 'L.',$,

Working Card 514-01.l

0
Page 1 (5) Fuel Injection Valve (L'Orange) Edition 08H

Safety precautions Special t o o l s

Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cooling water 52014 013
• Shut-off fuel oil 52014 407
E Stopped lub. or1 c~rcul 52014 050
Press Block~ng- Reset 5201 4 074

Description

Dismounting, overhaul, pressure testrng and

mounting of fuel injection valve.

Starting position H a n d tools

Top cover on the cylinder head and front cover on Ring and open end spanner 12 mm
the fuel injection pump has been dismounted. Ring and open end spanner 24 mm
Fuel injection pipe dismounted 514-01.05 Socket spanner 24 mm
Socket spanner 30 mm
Tools for cleaning.
Clean kerosene or gas oil.
Antiseizure product.
(Copaslip, Molykote GN Plus or similar).

Related procedure

Manpower Replacement and wearing parts

Working time : 2 hours Plate no Item no Qtyl

Capacity 1 man
51402 116 31valve
Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

01.44 - €SO 0406 ---

E E-=
-L_-
-W---
- ----
==-=-
GENERATINGSEr5
 514-01.10 Fuel Injection Valve (L'Orange)
Working Card
Edition 08H Page 2 (5)

The fuel injection valve is the single component that
has the greatest influence on the diesel engine
condition. Various forms of operation and quality of
fuel oil affect the overhaul intervals. In some cases
it may be necessary to shorten the prescribed inter-
vals.
6) Loosen the nozzle nut (5). If it isjammed, then
heat the n o u l e nut up in hot oil.
7) Remove the injector nozzle (6). Be careful that
the the injector needle does not fall out.

Attention
Dismounting a n d Cleaning
Do not damage the lapped surface.
1) Dismount the fuel injection valve from the
cylinder head by means of the special tool as 8) Dismount all other components.
shown in fig 7.
9) All parts must be cleaned with kerosene or gas
2 ) Mount the fuel injection valve on the pressure oil and a hard brush (not a steel brush).
testing pump.
10) Clean the nozzle holes of charred coke by
Note: Utmost cleanliness and care are required means of the supplied special drill please s e e
during the disassembly of fuel injection valve. plate 52014 with holder.

3) Loosen thenut, s e e f i g 2 , p o s 2 . 11) Clean carefully the injector body by placing

these in a cleaning liquid and then blowthrough
4) Then release the pressure spring (3). the parts with dry air.

5 ) Clean the lower part ofthe nozzle from carbon-

ized oil disposits.

a /'
l 2

l
Extractor
l

U
a /------S

>4

P
Fuel valve

/ 5

/6

1 Adjusting screw 4 0-rings

2 Nut 5 Noule nut
3 Pressure spring 6 Injector nozzle

Fig I Tool for dismounting of fuel injection valve. Fig 2 Fuel injection valve

-
=
-=
- - m
--M--
---
E
---
=-
= -
m
6 M R A T Y U C SETS
0406 01.44 - ESO
 Working Card
Page 3 (5) Fuel Injection Valve (L'oraflge)
Inspection of the Parts
12) Nozzles are matched by lapping and are there-
fore only interchangeable as units.
13) The injector needle, which has been previ-
ously cleaned, wetted by test 011P3 gero cut S
102 or diesel fuel and inserted into nozzle
body, is pulled out to approx. one third of its
sliding surface. At an almost vertical position,
the injector needle must quickly slide onto the
tight seat by its deadweight. This check-up has
to be carried out for three almost uniformly
distributed turning position of the needle.
14) If the holes are oval worn, which is checked by
means of a magnifying glass, the nozzle must
be scrapped.
15) The best way, however, to check if the holes
are worn out is to control the flow rate of the
nozzle which, in general, only can be made at
the manufacturer's works on a special test
stand.
16) Every effortto refurbish will result in alterations
of these values and malfunction of the nozzle.
If heavy abrasion symptoms, respectivelydam-
ages are observed at the visual inspection of
the parts, the parts in question must be re-
placed.
Reassembling
17) When all parts have been overhauled,found in
good order and carefully cleaned, assemble
the fuel injection valve again.
18) When assembling the fuel injection valve, pro-
ceed in the opposite order compared to the
disassembly. Pay attention to the following:
N injection valve must not leak during this check-
7
m
9
a. Lubricate the threads on the adjusting screw,
d
e fig. 2, pos. 1,with lub. oil, and the threadsof the
I 0
L0
m
N
nozzle holder for the nozzle nut. The shoulder
I I of the nozzle which is in contactwith the nozzle
0
4
m
. nut, must be lubricated with an antiseizure
N
m
0 product.
0
b. The sealing plane surface of body and nozzle
must be wiped dry with paper.
01.44 - ESO 0406
51Edition
4-01O.l~0
H
c. Renew the 0-rings (pos 4, fig 2).
d. Tighten torque for lock nut (2): 100 Nm.
Pressure Testing o f Fuel Injection Valve
19) The most effective checking of the fuel injec-
tion valves is obtained through pressure test-
ing, preferably carried out after each overhaul
and also in case of irregularities in operation.
The pressure testing is carried out in the fol-
lowing way by means of the pressure testing
apparatus supplied.
20) Mount the fuel injection valve in the test tool
again. The bracket to be in such a position that
the nozzle of the injector is pointing down-
wards.
21) To flush off possibly existing dirt particlesin the
fuel system of the injection valve, it is recom-
mended to pump through fuel several times,
while the released pressure spring (3) of the
nozzle holder is increase pressure by means
of the lever on the test pump, and adjust the
opening pressure to 450 bar, by the adjusting
screw ( l ) ,see fig. 2, then tighten lock nut (2)
and check opening pressure again.
The fuel injection valve shall properly spray at
a purnpingfrequency of approx. 1 to 2 strokes1
second, do not expect chattering. The fuel
(MDO) must be atomized by uniformjets. After
thejets arecut off, nofuel (NIDO) drop shall fall
down from the bottom of the spraying ball
during 10 seconds when the injector n o u l e is
vertically placed. Do not expect a nozzle tip
with more than l000 running hours to perform
like a new nozzle in the test pump.
23) All connecting and attached points of the fuel
"P.
Ifthe test conditions are not fulfilled it is necessary to
demount the fuel injection valve to determine the
causes. For that purpose, check the slidability of the
injector needle and that the injection nozzle is not
jammed in the nozzle holder.
---
-- -----
W
----
L===
S I==
- --
---W-
GENERATW SETS
 514-01 .l
0 Fuel hjectioll Valve (L'orange)
Edition 08H
No Jamming
If the injector nozzle is deformed by the tightening of
the nozzle nut (5), the injector needle will be jammed
in the nozzle body. Then fuel will be leaving thespray
holes as not or only partially atomized straight jet
only. Tightening torque for nozzle nut (5) 120 Nm.
l l
Fig 3 Grinding tool for seat and liner for fuel injection valve.
Conditions of Labour Safety
The fuel jets must not be touched under any circum-
stances as they hit through the skin tissue, and
cause blood poisoning. Urgently comply with the
regulations on fire prevention when handling inflarn-
mable liquids.
Mounting of the Fuel lnjection Valve in Cyl-
inder Head
24) Before mounting the fuel valve, clean and
inspect the valve sleeve in the cylinder head. If
- necessary, grind the seating face with the
grinding tool, see fig 3.
Working Card
Page 4 (5)
Assembly of the Injection Valve
25) Coat the 0-rings at the injection valve with
graphite paste.
26) The injection valve has to be inserted into the
cylinder head. Care for the alignment of the
high-pressurecone connection. Thealignment
of the injection 'valve is ensured by tightening
the pressure piece before tightening the injec-
tion valve.
Assembly of the Pressure Piece
27) Pull off the irnrnosion-melting coating from the
pressure piece. Blow the fuel borehole clean
by air to remove dirt. Renew and coat the 0-
ring (pos 7, fig4) for the sealing in the cylinder
head with graphite paste.
28) Carefully insert the pressure piece together
with spring lockwashers into the cylinder head.
Press the pressure piece thoroughly by hand
down to the sealed seat of the injection valve.
29) The nut including the guiding gasket has to be
screwed on the stud bolt. The pressure piece
must be turned dockwise up to the stop of the
spring lock washer. Tighten the nut with 28
Nrn. Care that the wrench is not pressed
against the pressure piece. The tightening
torque is then to small in this case and leak-
ages will be the consequence.
1 0-ring
2 0-ring
~ i 4gFuel injection pipe.
01.44 - ESO
 Working Card
Fuel Injection Valve (L'Orange)
Page 5 (5)
30) When the pressure piece has been tightened,
the fixing flange for the injection valve must be
plugged on. The washers and nuts have to be
attached or screwed on. The injection valve is
pressed to the sealed seat by an alternate
tightening of the nuts. The nuts shall be tight-
ened with 9 Nm and with use of antiseizure
products.
Assembly of the Pressure Pipe
31) Renew O-ring (pos 2, fig. 4), and coat the high-
pressure connecting threds at the pump and at
the pressure piece including the O-rings.
01.44 - ESO
514-01 .l
0
Edition 08H
32) Screw the pressure pipe manuallyto the pres-
sure piece.
33) The correct positioning of the sealing cone
from the pressure pipe has to be checked at
the pump. The sealing cone must be com-
pletely ummersed into the pressure nozzle of
the injection pump (approx. 3.6 mm). The
sleeve nut has to be screwed manually to the
pressure socket of the injection pump.
34) Tighten the sleeve nut at the pressure piece
with 65 + 5 Nrn.
35) Tighten the sleeve nut atthe connecting socket
of the pump with 65 + 5 Nm.
 ZJMD - =&W

Working Card
Fuel Injection Valve (Woodward) 514-01.l
0
Page 1 (5) Edition 09H

Safety precautions

E Stopped engine
E Shut-off starting air
r
Special tools

Plate no Item no Note

Shut-off cooling water

H Shut-off fuel oil
E Stopped lub. oil circul.
Press Blocking - Reset

I Description

Dismounting, overhaul, pressure testing and

mounting of fuel injection valve.

Starting position Hand t o o l s

Top cover on the cylinder head and front coveron Ring and open end spanner 12 mm
the fuel injection pump has been dismounted. Ring and open end spanner 24 mm
Fuel injection pipe dismounted 514-01.05 Socket spanner 24 mm
Socket spanner 30 mm
Tools for cleaning.
Clean kerosene or gas oil.
Antiseizure product.
(Copaslip, Molykote GN Plus or similar).

Related p r o c e d u r e

Manpower Replacement and wearing parts

Working time : 2 hours Plate no Item no Qtyl
Capacity 1 man
51402 116 31valve

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)
 514-01.10 Fuel Injec,tion Valve (Woodward)
Working Card
Page 2 (5)
Edition O9H

The fuel injection valve is the single component that
has the greatest influence on the diesel engine
condition. Various forms of operation and quality of
fuel oil affect the overhaul intervals. In some cases
it may be necessary to shorten the prescribed inter-
vals.
6) Loosen the nozzle nut (5). If it isjarnmed, then
heat the nozzle nut up in hot oil.
7) Remove the injector nozzle (6). Be careful that
the the injector needle does not fall out.

Attention
Dismounting a n d Cleaning
Do not damage the lapped surface
I) Dismount the fuel injection valve from the
cylinder head by means of the special tool as 8) Dismount all other components
shown in fig I .
9) All parts must be cleaned with kerosene or gas
2) Mount the fuel injection valve on the pressure oil and a hard brush (not a steel brush).
testing pump.
10) Clean the nozzle holes of charred coke by
Note: Utmost cleanliness and care are required means of the supplied special drill please see
during the disassembly of fuel injection valve. plate 52014 with holder.

3) Loosen the nut, see fig 2, pos 2. 11) Clean carefully the injector body by placing
these in a cleaning liquid andthen blowthrough
4) Then release the pressure spring (3). the parts with dry air.

5) Clean the lower part of the nozzle from carbon-

ized oil disposits.

Extractor

Fuel valve

1 Adjusting screw 4 0-rings

2 Nut 5 Nozzle nut
3 Pressure spring 6 Injector nozzle

Fig 1 Tool for dismounting of fuelinjection valve Fig 2 Fuel injection valve.

--
=
- ===
--
= =-
---==
L
=
C*=-
CENEQKTNC SETS
- 01.44 - ESO
 ZJMD - B&W
Working Card
Fuel Injection Valve (Woodward)
Page 3 (5)
Inspection o f t h e Parts
12) Nozzles are matched by lappingand are there-
fore only interchangeable as units.
13) The injector needle, which has been previ-
ously cleaned, wetted by test oil P3 gero cut S
102 or diesel fuel and inserted into nozzle
body, is pulled out to approx. one third of its
sliding surface. At an almost vertical position,
the injector needle must quickly slide onto the
tight seat by its deadweight. This check-up has
to be carried out for three almost uniformly
distributed turning position of the needle.
14) If the holes are ovai worn, which is checked by
means of a magnifying glass, the nozzle must
be scrapped.
15) The best way, however, to check if the holes
are worn out is to control the flow rate of the
nozzle which, in general, only can be made at
the manufacturer's works on a special test
stand.
16) Every effortto refurbish will result in alterations
of these values and malfunction of the nozzle.
If heavy abrasion symptoms,respectivelydam-
ages are observed at the visual inspection of
the parts, the parts in question must be re-
placed.
Reassembling
17) When all parts have been overhauled,found in
good order and carefully cleaned, assemble
the fuel injection valve again.
18) When assembling the fuel injection valve, pro-
ceed in the opposite order compared to the
disassembly. Pay attention to the following:
N injectionvalve must not leak during this check-
m
7 a. Lubricate the threads on the adjusting screw,
9
.
a
TI
a
LD
N
fig. 2, pos. I ,with lub. oil, and the threads ofthe
nozzle holder for the nozzle nut. The shoulder
In
F of the nozzle which is-incontact with the nozzle
n
4
m nut, must be lubricated with an antiseizure
N
m
0 product.
0
b. The sealing plane surface of body and nozzle
must be wiped dry with paper.
01.44 - ESO 0406
514-01.10
Edition 09H
c. Renew the O-rings (pos 4, fig 2).
d. Tighten torque for lock nut (2): 50 Nm
Pressure Testing of F u e l Injection Valve
19) The most effective checking of the fuel injec-
tion valves is obtained through pressure test-
ing, preferably carried out after each overhaul
and also in case of irregularities in operation.
The pressure testing is carried out in the fol-
lowing way by means of the pressure testing
apparatus supplied.
20) Mount the fuel injection valve in the test tool
again. The bracket to be in such a position that
the nozzle of the injector is pointing down-
wards.
21) Toflush off possibly,existingdirt particles in the
fuel system of the injection valve, it is recom-
mended to pump through fuel several times,
while the released pressure spring (3) of the
nozzle holder is increase pressure by means
of the lever on the test pump, and adjust the
opening pressure to 450 bar, by the adjusting
screw ( l ) ,see fig. 2, then tighten lock nut (2)
and check opening pressure again.
22) The fuel injection valve shall properly spray at
a pumpingfrequency of approx. 1to 2 strokes1
second, do not expect chattering. The fuel
(MDO) must be atomized by uniform jets. After
the jets arecutoff, no fuel (MDO) drop shall fall
down from the bottom of the spraying ball
during 10 seconds when the injector nozzle is
vertically placed. Do not expect a nozzle tip
with more than l000 running hours to perform
like a new nozzle in the test pump.
23) All connecting and attached points of the fuel
'JP.
If the test conditions are not fulfilled it is necessary to
demount the fuel injection valve to determine the
causes. For that purpose, check the slidability of the
injector needle and that the injection nozzle is not
jammed in the nozzle holder.
- _---- -
-
- --- --a
CENERATNC SETS
5
 514-01.l
0 Fuel Injection Valve (Woodward)
Edition 09H
No Jamming
If the injector nozzle is deformed by the tightening of
the nozzle nut (5), the injector needle will be jammed
i n the nozzle body. Then fuel will be leaving thespray
holes as not or only partially atomized straight jet
only. Tightening torque for nozzle nut (5) 200 Nm.
Fig 3 Grinding tool for seat and liner for fuel injection valve.
Conditions of Labour Safety
The fuel jets must not be touched under any circum-
stances as they hit through the skin tissue, and
cause blood poisoning. Urgently comply with the
regulations on fire prevention when handling inflarn-
mable liquids.
Mounting of the Fuel lnjection Valve in Cyl-
inder Head
24) Before mounting the fuel valve, clean and
inspect the valve sleeve in the cylinder head. If
necessary, grind the seating face with the
grinding tool, see fig 3.
r ===
p p* S-=-
== =
GENERATNG SETS
Working Card
Page 4 (5)
Assembly of the lnjection Valve
25) Coat the O-rings at the injection valve with
graphite paste.
26) The injection valve has to be inserted into the
cylinder head. Care for the alignment of the
high-pressurecone connection. The alignment
of the injection valve is ensured by tightening
the pressure piece before tightening the injec-
tion valve.
Assembly of the Pressure Piece
27) Pull off the immosion-melting coating from the
pressure piece. Blow the fuel borehole clean
by air to remove dirt. Renew and coat the 0 -
ring (pos I , fig 4) for the sealing in the cylinder
head with graphite paste.
28) Carefully inser the pressure piece together
with spring lockwashers into the cylinder head.
Press the pressure piece thoroughly by hand
down to the sealed seat of the injection valve.
29) The nut including the guiding gasket has to be
screwed on the stud bolt. The pressure piece
must be turned clockwise up to the stop of the
spring lock washer. Tighten the nut with 28
Nrn. Care that the wrench is not pressed
against the pressure piece. The tightening
torque is then to small in this case and leak-
ages will be the consequence.
~
Fig 4 Fuel injection pipe
01.44 - ESO
 Working Card
Page 5 (5) Fuel Injection Valve (Woodward)
30) When the pressure piece has been tightened, 32)
the fixing flange for the injection valve must be
plugged on. The washers and nuts have to be
attached or screwed on. The injection valve is 33)
pressed to the sealed seat by an alternate
tightening of the nuts. The nuts shall be tight-
ened with 9 Nrn and with use of antiseizure
products.
Assembly of the Pressure Pipe
34)
31) Renew O-ring (pos 2, fig. 4), and coat the high-
pressureconnecting threds at the pump and at
the pressure piece including the O-rings. 35)
01.44 - ESO
4-01O .l
51Edition ~0
H
Screw the pressure pipe manually to the pres-
sure piece.
The correct positioning of the sealing cone
from the pressure pipe has to be checked at
the pump. The sealing cone must b e corn-
pletely ummersed into the pressure nozzle of
the injection pump (approx. 3.6 mm). The
sleeve nut has to be screwed manually to the
pressure socket of the injection pump.
Tighten the sleeve nut at the pressure piece
with 65 + 5 Nm.
Tighten the sleeve nut atthe connecting socket
of the pump with 65 + 5 Nrn.
 ' MAN ':
B&W I

Working Card
Check of Fuel Oil Piping System
514-01.90
Page 1 (2) Edition 04H

Safety precautions Special tools

Stopped engine Plate no ltem no Note

Shut-off starting air
Shut-off cooling water
D Shut-off fuel oil
Stopped lub. oil circul.
Press Blocking - Reset

Description
Hand tools
Check of fuel oil piping system.

Starting p o s i t i o n

Engine is running.

Related p r o c e d u r e

Manpower Replacement a n d wearing parts

Working time : % hour Plate no Item no Qty. 1

Capacity l man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

01.08 - ESO
514-01.90 Check of Fuel Oil Piping System
Edition 04H
Fuel Oil System
Important for starting u p n e w engines or newly
overhauled engines!
The system includes all parts in the internal fuel oil
system, ie main components as pumps, high pres-
sure pipes, pressure piece, injection valve and all
types of connections, all types of pipes as well as
leakage alarm and safety filter.
These components have to b e checked at intervals
accordingto the "Planned maintenance programme".
I) Dismount the covers to the injection pumps.
Blow through drain pipes.
2) Examine the piping system for leaks. No outer
leaks can be permitted.
3) Retighten all bolts, nuts and plugs in the piping
system. Especiallydoes all high pressure parts
have to be tightened correctly. Please, see
working cards in section 514 "Fuel Oil system".
Working Card
Page 2 (2)
4) Move all valves in the piping system.
Lubricate valve spindles with graphite or simi-
lar.
5) Check flexible connections for leaks and dam-
ages.
It is important that the flexible connections are free
from paint and grease and in healthy condition.
6) Check for any leak of the 0-ring for the fuel
injection pipe.
When the engine has reached normal working tem-
perature and no later than 24 operating hours after
starting up, the complete fuel oil system has to be
checked according to the above-mentioned instruc-
tion book working card "Check of the fuel oil piping
system".
If the above instructions are not followed carefully,
there is a risk of 011leakage that can result in
dangerous vaporised fuel emission into the engine
room.
Concerning fuel oil condition, see section 504.
01.08 - ESO
 Plate
Page 1 (2) Fuel lr~jectionPump (Woodward) 51401-04H

00.50 - ESO
 ZJMD - B&W

51401-04H Fuel Injection Pump (Woodward) Page 2 (2)

Plate

Itern I
No Qty 1 Designation Beni~vnelse
Item
No
I
Qty I Designation
I
Benievnelse
l
Roller guide, com- Rullestyr, kornplet inkl.
plete incl. item 026, itern026,038,051,063,
278 ( lip Spring plate Fjederplade

/
038, 051, 063, 075, 075,408 291 lip Pump spring Pumpefjeder
408 l

026. I I l/P Roller Rulle

301" IIP valve Fjeder for
trykventil

038' 1 1/P Roller pin Rulletap 313. 1 l/P Stroke limiter Begr~nser

051' 1 1/P ; Roller guide Rullestyr Blocking screw Skrue

l l

063 ) l i p Holding screw Skrue Guiding screw Styreskrue

1
075 1 l i p 1 Cylindrical pin Cylindrisk stift Locking screw Liseskrue
i

Pump element, com- Pumpeelernent, kom- Throttle screw Skrue

plete incl. item 099, plet inkl. item 099, 109,
109,110 110 Pointer Viser

099. / l/P Barrel Cylinder 374 1 I lip stop plate Stopplade

109. ( l/P
!
Plunger Stempei 386 ( 1 l/P Sealing Tstning

398 1 4lP 1 Cylindrical screw Cyindisk skrue

Pressurevalve, corn- Ttykventil, kornplet inkl.

plete incl. item 134, itern134,146,158,301,
408 / I l/P Cylindrical screw Cyliniisk sirue

1 I
134' / lP
!
146,158,301,313

Pressure valve
housing
313

Hus for trykventil

421

433 I
6/P

IIP
Cylindrical screw

Pan head screw

Cylindrisk skrue

Skrue

Constant pressure Konstant trykventil

valve

Pressurepiece, corn- Trykstvkke, k o m ~ l e t 470 ZP Seal ring T~tningsring

plete incl. item 183, inkl.iteh 183,195,205, i i
195,205,217 217 482 1 ZP Seal ring Tztningsring

Slotted disk Skive Seal ring Tztningsring

Spacer plate Afstandsplade Seal ring Tztningsring

Thrust piece Trykstykke Fitting disk Skive

Countersunk screw Skrue Fitting disk Skive

Pump casing Purnpehus Fitting disk Skive

N
7

Connecting piece Forbindelsesstykke Fitting disk Skive m:

o
0'
Buffer bolt Bolt Fuel Injection Pump, Brzndselspurnpe, F
565 1IC 0
complete as shown kornplet som vist p5 U7
L0
N
Control rack Regulenngsstang o n front page foniden F
0
Control sleeve Kontrolbosning 0-ring 0-ring 4
984 1/C m
N
0
m
0

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs5 side 500.50.
= Only available as part of a spare parts kit. = Kun tilgaengelig sorn en del af et reservedelssaet.
-- QtyIC = Qty/Cylinder QtyIC = QtylCylinder
QtylP = QtylPump QtylP = QtyIPurnpe

00.50 - ESO
 Plate
Page I(2) Fuel Injection Pump (L'Orange) 51401 -07H

01.08 - ESO 0406 --

--
- --
L
- ---
=== W-
-=
a--

EGEC~XTKGY~~S
=-
 ZJMD -
51401-07H Fuel Injection Pump (L'Orange) Page
Plate
2 (2)

ltem
No 1I Qty Designation Benzvnelse
ltem I
No
I
/
Qty Designation Benaevnelse

/ I'
I
014 l/P Roller guide, som- Rullestyr, komplet ink1

( 1 plete incl. item 026, item 026,038, 051,063

I
038. 051.063

026' l/P Roller 482' I1P Seal rlng Tatn~ngsr~ng

038' 1 1 l/? Roller pin Rulletap 516

l

l/? Shim, Mellemlzg,

051. 1 l/P Roller guide Rullestyr

565 1
set of 4 pcs s z t af 4 stk

Fuel Injection Pump, Brzndselspurnpe,

063' 1 1/P 1 Bolt Bolt complete as shown komplet som v~stp5
l on front page fors~den
087 1/P I Pump element, corn- Purnpeelenen:. kon-
1
plete incl. item 099, plet inkl. item 033. 1CO
! 109, 110, 183, 697, 110, i83, 637.7Ci
577 :/P Cylindrical pin Cylindrisk stift

i
707 1 Skrue

!
Cylinder 697' 1 2/P I Supportring Stattering

109' 1 1/P ) Plunger Sternpel

756 / 1 lip Circlip Snapring

768* / 6/P I Seal ring Tatningsring

183- ( 1P I Shim Skive 781. ! l/P I Lock ring Lbsering

205' / l/P / Piston spring plate Sternpelijederplade 793

l
1 I/P I screw plug Propskrue

229 1 l/P I Pump caring Purnpehus 803' lP Seal ring Tatningsring

230 1P 1 Connecting socket

I complete incl. valve
I cones, springs and
1 item 158,457,577
Forbindelsesstykke
komplet, inkl. ventrl-
815 1 lff
I
Pump spring corn- Purnpefjeder korn-
plete, incl. item 205, plet, inkl. item205,278,
spindler, fied:e og item j ( 278,291 29 1
158,457,577

242 1 l/? ( Buffer bolt Bolt

827 1 /I j ~ o c t i t e0577 Loctite 0577

254 1 lff Control rack Reguleringsstang

Seal kit for fuel in-
jection pump, incl.
item1 10, 158, 457,
Pakningss~tfor
brzmdselspurnpe,
inkl. item l10, 158,
(
266
1
lff
// Regulating sleeve Reguleringsbssning
inc1.clamping sleeve inkl.
469, 482, 697, 707,
756, 768, 781, 803,
984
457,469, 482, 697,
707,756, 768,781,
803,984
278' / lip 1 Spring plate Fjederplade

291- ( 1P Pump spring Purnpebeder

337 1 1 lff Arresting bolt Bolt

349 / 1 lff Blocking screw LAseskrue

362 / 1 lff Pointer Viser

1 /
421

433 1 / SIP

1P
Cylindrical screw

Countersunkscrew
Cylindrisk skrue

Skrue

When ordering spare parts, see also page 500.50. Ved bestitling af reservedele, se ogsi side 500.50.
= Only available as part o f a spare parts kit. = Kun tilgzngelig som en del af et reservedelsszt.
- QtylC = QtylCylinder Qty/C = Qty/Cylinder
QtylP = QtylPump Qtyff = Qty/Purnpe

01.08 - ESO
 Plate
Z J M D 64
mew

Page I(2) Fuel lnjection Valve (Woodward) 51 402-1 lH

,
8 8
,
,/--
S

Bolt, see plate 50501

;. /,

----
03.50- ESO 0406 --
- S A -

GENERA%
-
F=='
SETS
 Plate
51402-1 1H Fuel Injection Valve (Woodward) Page 2 (2)

Item i
no Qty
1
l
l
Designation Benavnelse IFom 1 1
1
~ t yDesignation Benavnelse

Dyse,
1200 rpm engine 1200 omdr. motor
l

045 1 IN (Nozzle nut Dysematrik 1

057 IN Pressure bolt Bolt

069
1
TN ) lidjusting spindle
,
Juslebar spindle

070 ! IN Pressure spring Trykijeder

l

094 1 I ZN Cylindrical pin Cylindrisk stift

116 l l/C Fuel injection valve, Brandselsventil, kom-

complete for 1200 r p m plet for 1200 omdr. rno-
engine, incl. item 021, tor, inkl. item 021,033.
033,045,057,069,070,045,057,069,070,082,
l 082,094,104,128 094.104,128

1 IN l
i
128 Nozzle holder Dyseholder
i
141 ( IN lPressurepiece Spandestykke

153 / 2 / ~l ~ u t Matrik l I
165 1 I ZN Sperical disc Skive
il
273 IN / Injection nozzle, Dyse,
1 1 l000 rpm engine 1000 omdr. motor
l
285 1 1/C Fuel injection valve, Brzndselsventil, korn-
completefor1000 r p m plet for 1000 omdr. rno-
engine, incl. item 033, tor, inkl. item 033,045,
045,057,069,070,082,
057,069,070,082,094,
094,104,128,273 104,128,273

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se o g s i side 500.50

= Only available as part o f a spare parts kit. = Kun tilg~ngeligsom en del af et reservedelsszt.
QtylC = QtyICylinder QtylC = QtyICylinder
QtyN = QtyNalve QtyN = QtyNentil

= === ==== 03.50- ESO

mFE? 0406
ESZGR~Y~h
 ZJMD - m8rw
Plate
Page I(2) Fuel Injection Valve (L'Orange) 1 51402-12H 1

...
,,, ,,

: :
/- Bolt, see plate 50501

- --- --
l
i 03.50- ESO 0406 -- ------
--
CE-WC
-
SE--
SETS
 Z J M D
(a,
Plate
51402-12H Fuel Injection Valve (L'Orange) Page 2 (2)

Item i
no Qty / l Designation Benawnelse
Item
no 1 Qty
I
Designation Benzvnelse
I l I l

021 1I IN Injection nozzle, Dyse,

1200 rpm engine 1200 orndr. motor
l

045 1 1N l Nozzle nut Dysernotrik

057

069
'/ 11NN /I
i
Pressure bolt

Adjusting spindle
Bolt

Justeba.spindle
I
070
i 1
' IN Pressurespring Trykfjeder

094 2N Cylindrical pin Cylindrisk stift

128 , IN ! Nozzle holder Dyseholder

141 / 1N l Pressure piece Sp~ndestykke

Skive

Dyse,
1000 rpm engine l 0 0 0 orndr. motor

285 l/C Fuel injection valve, Brandselsventil, kom-

completeforlOO0 rpm plet for 1000 omdr. mo-
engine, incl. item 033, tor. inkl. item 033, 045.
045,057,069,070,082, 057,069,070,082,094,
094,104,128,273 104,128,273

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se o g s i side 500.50.
= Only available as part o f a spare parts kit. = Kun tilgzngelig sorn en del af et reservedelsszt.
. -. QtyIC = QtyICylinder Qty/C = QtyICylinder
OtyN = QtyNalve QtyN = QtyNentil

03.50 - ESO
 ZJMD - 6&W

Plate
Page I(2) Fuel Injection Pipe (Woodward) 51404-06H

00.48- ESO -
_---- - -
- - ----
- ----
SE-TING
S=---
L _ _
-

SETS
[ MAN,
5 B&W i

Plate
51404-06H Fuel Injection Pipe (Woodward) Page 2 (2)

Item lten
no Qty Designation Benrevnelse no Qty Designation Benrevnelse

010 ( ~IC I P ~ ~ ~ ~ ~ ~ ~
piece Trykstykke
-

034 1 / 1IC Pressure pipe H~jtryksr~r

OB3 I I 1iC Holder, complete

incl. sleeve
Holder, komplet
inkl, b ~ s n i n g

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se o g s i side 500.50.
= Only available a s part of a spare parts kit. = Kun tilg~ngeligsorn en del af et reservedelssa3t
QtylE = Qty.lEngine QtyIE = Qty./Motor
QtylC = QtylCylinder QtyIC = QtyiCylinder

00.48 - ESO
 ZJMB - E&W

l Plate
Page 1 (2) I Fuel Injection Pipe (L'Orange)
 ~,<.:::?:
*ps:,' .L.
.c< ,
i.
t"
g M
U,..

:IS . B&" -

Plate
51404-07H Fuel Injection Pipe (L'Orange) Page 2 (2)

Item lten
no Qty Designation Bensevnelse no
-
010 IIC Pressure piece Trykstykke

022 1/C 0-ring 0-ring

034 1/C Pressure pipe Hojtryksror

046 1/C 0-ring 0-ring

083 1IC Holder, complete Holder, komplet

incl. sleeve ink. basning

095 1/C Nut Marrik

274 2iC 0-ring 0-rin~

When ordering spare parts, see also page 500.50. Ved bestilling af resewedele, se o g s i side 500.50
= Only available as part of a spare parts kit. = Kun tilgatngelig som en del af et resewedelss~t.
QtylE = Qty.lEngine QtylE = Qty./Motor
QtylC = QtylCylinder QtylC = QtylCylinder

00.48 - ESO
 Ptate
pase 1 Q) Safety Filter 5141541H

General
 1
Plate
5?425-0lH Safety Filter page 2 (2)

General

ZF
I Gasket Pakni~

When orderingspare pitrts, see atso page 5 0 0 3 . Ved bejtining af reserv&b, se ogd side 500.50.
= O n l y availabie as part of a spare partskit
QtylE = PtylEngine
gf
f = Qty/Fi&er
 Plate
Page 1 (2) Fuel Oil Arrangement 51430-02H

L Fuel oil leakage alarm,

024 see plate 50925 L 240

l
j
l
97.40 - ESO 0406 --
--
P
m-----
----
EL
---
-
--
--

CENERATNC SETS
 ZJMD - 6&W

Plate
51430-02H Fuel Oil Arrangement Page 2 (2)

Item
No Qty Designation Ben~vnelse Designation Benavnelse

012 /
1

2/E /Screw
l

Skrue
l
036 1 l / E (pipe Rar
I
Hus for
thermofeeler termofaler

/l ll
2/E Straight male stud Ligeforskruning
coupling
O6I
073 2/i Reduction Reduk;ion

085 1 l l/E Pipe clamp Rarholder

l
097 1 l/E Screw Skrde
I
107 ( 1/E l Pipe Rai
I
Straight male stud Ligeforskruning
coupling

Pipe Rerr

Pipe holder Rplrholder

Screw Skrue

Equal elbow coupling Vinkelforskruning

Pipe Rar

Adjustable elbow Justerbar

coupling vinkelforskmning

193 / l E /Equal elbowcoupling V~nkdfonkruning

203 ( l/E l Pipe Rerr

Straight male stud Ligeforskmning

coupling

Pipe Rsr

Pipe clamp Rsrholder

Slotted cheese head Kzervskrue

screw

When ordering spare parts, see also page 500.50. Ved bestillins af reservedele, se ogsA side 500.50.
= Only available as part of a spare parts kit. = Kun tilgzengelig som en del af et reservedeisszet
QtylE = QtylEngine QtylE = QtylMotor

E
7- -
E=-
= =
7-
~ Z ' T K G Y ~ S
= 0406 97.40 - ESO
 ,.!:...
*xY:A:3.:&".. b$
'-,
'+i
/.: MAN
4'
'
B&\H !j >?.

I Plate
Page 1 (2) l Fuel Oil Arrangement 1 51430-03H 1

L Fuel oil leakage alarm, Loop expansion joint,

see plate 50925 see plate 51 902

99.33 - ESO 0406 - -----

= === -=--E
P = =-
= -
E
CENERPITUYCSETS
-
 Plate
51430-03H Fuel Oil Arrangement Page 2 (2)

"om I 1 Qty Designation Benavnelse Qty Designation Benavnelse

012 I IIE (Screw Skrue 3/E Gasket Pakning

Skive 12/E Screw Skrue

'
l/E Pipe, Rsr, 3lE Packing ring Pakningsring
fuel oil inlet tilgang briendoiie
*/E Screw Skrue
2/E Straight male stud Ligeforskruning
coupling 4/E Screw Skrue

2/E Reduction IZIE I Nut Motrik

1/E Pipe clamp Rsrholder ?/E Pipe, R0r,

fuel oil outlet afgang brandolie
1E Screw Skrue
l/E 1 Pipe, drain Rsr, drien

lo7
IIE
I I l/E Pipe,
fuel oil outlet

Straight male stud

Rsr,
afgang brandolie

Ligeforskruning
2/E Pipe,
fuel oil inlet
Rsr,
tilgang b r ~ n d o l i e

coupling 1/E Bracket Konsol

1/E Pipe, drain Rsr. drien 1IE Pipe clamp R~rholder

?/E Pipe holder Rorholder 2iE Screw Skrue

Skrue

Adjustable elbow Justebar

coupling vinkelforskruning

/ Pipe Rar

Adjustable elbow Justerbar

coupling vinkelforskruning

Adjustable elbow Justerbar

coupling vinkelforskruning

1 Pipe Rsr

1/E Straight male stud Ligeforskruning

coupling

1/E Pipe Rsr

239 / 5/E /Pipe clamp Rsrholder

/1 11
5/E Slotted cheese head K~ervskrue
screw
240
252 l/E Non-return valve Kontraventil

3/E Straight male stud Fonkruning

coupling

I
1/E Screw Skrue

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se o g s i side 500.50.
= Only available as part o f a spare parts kit. = Kun tilgsngelig sorn en del af et reservedelss~t
Qty/E = QtyIEngine Qty/E = Qty/Motor

99.33 - ESD
 &d,#>:!~:2 >G,;
/"'
\-
"K-

MAN \
k B&W 1

Plate
Page I( 2 ) Fuel Injection Pump Connections (L'Orange) 51435-03H

Fuel injection pump,

see plate 51401

\ Fuel injection pipe,

see plate 51404

00.50- ESO --
L A--

--W---
-----
- ----- - -
- -
---
p

---
W

GENERATING SETS
 Plate
51435-03H Fuel Injection Pump Connections (LIOrange) Page 2 (2)

Itern Item
No Designation Benavnelse No Designation Benrevnelse
Qty
- Qty

) sic I
I l
021 screw Skrue

057 1 1 llC Spring pin Fjederstifl

lnsert pipe R0r

5 cyl. engine 5 cyl. motor
6 cyl. engine 6 cyl. motor
7 cyl. engine 7 cyl. motor
8 cyl. engine 8 cyl. motor
9 cyl. engine 9 cyl. motor

070 1 I 4iC Retaining ring Sikringsring

Insert pipe RB:

5 cyl. engine 5 cyl. motor
6 cyl. engine 6 cy!. motor
7 cyl. engine 7 cyl. motor
8 cyl. engine 8 cyl, motor
9 cyl. engine 9 cyl. motor

094 1 2iC 1 Retaining ring Sikringsring

104 / I ZE Plug Prop

Prop

l41 / llE I Screw Skrue

I53 I llE ( Cover plate Dzekselplade

1 1
1 1
165 21E Screw Skrue

l77 21E Stud

189 / lE 1 Connectingsocket Forbindelsesstykke

224 I 2lE ( Connecting pipe Forbindelsesror

Forbindelsesror

When ordering spare parts, see also page 500.50. Ved bestiiling af reservedele, se ogs5 side 500.50
= Only available as part o f a spare parts kit. = Kun tilgzengelig sorn en del af et reservedelsszet
- QtylE = QtylEngine QtyIE = QtyIMotor
QtylC = QtylCylinder QtyIC = QtyICylinder

---
---- - -
-----
- m- 00.50 - ESO
-TIffi SETS
 ZJMD - B&W

Plate
Page I(2) Fuel lnjectio~iPump Connections (Woodward) 51435-04H

Fuel injection pump,

see plate 51401

\ Fuel injection pipe,

see plate 51404

00.50 - ESO 0406 -- ---

-- -
= = -=
-- --=-
-p-
GENERATNO SETS
 Fuel Injection Pump Connections Plate
Page 2 (2)

Item Item
No Qty Designation Ben~vnelse No Designation Benamelse
Qty

021 5/C Screw Skrue

045 1/C O-ring O-ring

057 l1C Spring pin Fjederstift

069 Insert pipe Rar

8IE 5 cyl. engine 5 cyl. motor
lOlE 6 cyl. engine 6 cyl. motor
12/E 7 cyl. engine 7 cyl. motor
14/E 8 cyl. engine 8 cyl. motor
16/E 9 cyl. engine 9 cyl. motor

070 41C Retaining ring Sikringsring

082 Insert pipe Rar

4/E 5 cyl. engine 5 cyl. motor
5/E 6 cyl. engine 6 cyl. motor
6/E 7 cyl. engine 7 cyl motor
7/E 8 cyl. engine 8 cyl. mobr
8lE 9 cyl. engine 9 cy moror

094 2/C Retaining ring Sikringsdng

104 2iE Plug Prop

116 1/E Plug Prop

128 1E Sheet Plade

141 1E Screw Skrue

153 1E Cover plate Dzkselplade

165 2/E Screw Skrue

177 2/E Stud Tap

189 1/E Connecting socket Forbindelsesstykke

190 2E Nut Matrik

200 2/E O-ring O-ring

212 1E O-ring O-ring

224 Z/E Connecting pipe Forbindelsesrar

236 1E Connecting pipe Forbindelsesrar

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se o g s i side 500.50.
= Only available as part o f a spare parts kit. = Kun tilgzngelig som en del af et reservedelsszt.
Qty/E = QtylEngine
QtyE = Qty/Motor
Qty/C = QtylCylinder

-- ---
- --
---
--
--
- --
--
EGGF~Z-TRET~S 0406 00 50 - ESO
 Lubricating Oil System

/Internal lubricating oil system 1

--
l
' ~ u b r i c a t i n011
~ pump k l 5 - 0 2 . 0 0 (038) i
!
j ~ r e l u b r r c a t ~pump
n~ 1515-3r.05 ( O i M j Ii
1 3

;Lubricat~ng011frlter i515-01.10 f828-f) ,

r- S - . -

tLubr~catingoll, thermostatic valve j515-01.2Q ( 0 3 H ) 1

/check of lubr~catingo ~ piping
l system ,515-01.90( 0 2 H )
l
l
iLubrlcatrng or cooler 1535;-OQ.QO (83H) I
1
kentrlfuqal by?ass illter l51s-ls.oa (ssw2 l

/ ~ u b r i c a t l n011~ pump
I
'515OE-O6H 1
!
,Lubricating 011filter 515@2-04H
-- - - I
1
iPrelubr~catlngpump
- - -- .. -
5i504-028 1l
l
i~ubricatrngoil cooler 51506-033 l
l
l
;Centrifugal bypass fllter 5152.S-02Fi 1
#-

/~ubricatingoil separator j54530-oZE

i1
i~relubricatingpump arrangement
. - -
i53.535-02H 1
 ZJMD - E&W

Description 515.01
Page I(2) Internal Lubricating Oil System Edition O ~ H

Froni-end box -'

I l

Fig 1 Diagram for Internal Lubricating Oil System

Lubricating Oil System The main groups of components to be lubricated are:

All moving parts of the engine are lubricated with oil 1 - Turbocharger.
circulating under pressure. 2 - Main bearings, big-end bearing etc.
3 - Camshaft drive.
System Flow 4 - Governor drive.
5 - Rockerarms.
The lubricating oil pump draws oil from the oil sump 6 - Camshaft.
and pushes the oil through the cooler and filterto the
main lubricating oil bore, from where the oil is distri- ad 1) For priming and during operation the turbo-
buted tovarious lubricatingpoints. Fromthelubricating charger is connected to the lub. oil circuit of the
points the oil returns bygravityto the 011sump.The oil engine. The oil serves for bearing lubrication
pressure is controlled by an adjustablespring-loaded and also for dissipation of heat.
relief valve built into the system.
ad 2) Lubricating oil for the main bearings is sup-
plied through holes in the engine frame. From
the main bearings it passes through bores in the
crank-shaftto the connecting rod big-end bea-
rings.

98.50- ESO
515.01 Descr~pt~on
Ed~t~o n
04H
Internal Lubricating Oil S y s t e m Page 2 (2)

Channels have been bored into the connecting L u b r i c a t i n g Oil C o o l e r

rods for supply of oil from the big-end bearings
to the small-end bearings, which has an inner
circumferential groove, and a pocket for distri-
bution of oil in the bush itself. For supply of oil
to the pin bosses and the piston cooling.
From the front main bearings channels have
been bored in the crankshaft for lubricating of
the pump drive.
ad 3) The camshaft drive gear wheels are being
lubricated via the oil-mist principle. Oil-mist is
being generated by o I, which isled outfrom the
bearing in the intermediate wheels.
ad 4) From bores in theengine frarnethe governor
drive is being pressure lubricated.
ad 5) The lubricating oil to the rocker arms is led
through bores in the engine frame to each
cylinder head. The oil continues through bores
in the cylinder head to lubricate the rocker arms
and valve bridges. Further, lub oil is led to the
movable parts in need of lubrication.
ad 6) Lubrication to the fuel pump is supplied via
the fuel camshaft bearing.
The lubricating oil cooler is of the plate type. The
cooler is mounted on the front-end box.
T h e r m o s t a t i c Valve
The thermostatic valve is a fully automatic 3-way
valve with thermostatic elements set at fixed tem-
perature.
L u b r i c a t i n g Oil Filter
The lubricating oil filter is a full-flow depth filter of the
duplex paper cartridge type, with a fineness of 10-15
microns, and a safety filter with a fineness of 60
microns.
The engine is equipped with an electric-driven prelub.
pump mounted parallel to the main pump. The pump
is arranged for automatic operation, ensuring stand-
still of the prelubricating pump when the engine is
running,and runningdunng enginestand-st~llinstand-
by position by the engine control system.

L u b r i c a t i n g Oil Pump

The lubricating oil pump, which is of the helical gear

type, is mountedin thefront-end boxofthe engineand
is driven by the crankshaft.

98.50 - ESO
 Working Card
Lubricating Oil Pump 515-01.OO
Page 1 (3)
Edition 03H

Safety p r e c a u t i o n s Special t o o l s

Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
E Stopped lub. oil circul.
G Press Blocking - Reset

) Description Hand t o o l s
Disassembly, overhaul and assembly of lubrica- Feeler gauge 0.1 mm! min length 40-50 cm
ting oil pump Feeler gauge 0.3 mm, rnin length 40-50 cm
Feeler gauge 0.35 mm, min length 40-50 cm

Starting position

Lubricating oil cooler 51 5-06.00

l
Related procedure

Manpower R e p l a c e m e n t and.w e a r i n g p a r t s

Working time : 1 hours Plate no Item no Qtyl

Capacity 1 man

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.47- ESO -- ----

--
E E
- ----
t = E===
- - m

CENERATNC SETS
 ZJMD -
Working Card
Edition 03H
Lubricating Oil Pump Page 2 (3)

Preparing b e f o r e D i s m o u n t i n g Mounting

For access to the lubricating oil pump it is necessary 8) Change the 0-rings on the pump.
to remove the lubricating oil cooler. Please see
worcking card 515-06.00. 9) Mount the pump by the bolts and tighten these
according to description 500.40.

Dismounting 10) Re-newthe 0-ringsforoil and water connections

to the lub. oil cooler.
1) Remove the bolts which are holding the lub. oil
Pump. 11) Mount the lub. oil cooler to the frame plate.
.-
2) Use the spring bolts to push out the pump.
U
Overhaul

3) Removethe bolt(1)andthespurwheel (2), see

T7g I .
i
4) Remove the bolt(3)and the cover (4), see fig I

Take out the pinion spindles (5) and clean all parts in
gasoil and with a hard bush, (neveruse asteel bush).
The parts are blown clean with working air.

5) Check the wear ofthe bearing bush.

I 1

6) Ifthe bearing bush IS to be removed the exist~ng

bearing bush is plugged out by means of a
, Lubnrahng al pump

- mandrel, the bores are cleaned, see fig 2, and

new bearing bush is mounted
The bush is cooleddown to -130°C, the hous~ng
or cover has room temperature.

Note: criteriaforreplacement of bearing bush, see A,

fig 3.
l

7) Mount the pinion spindels (5) the cover (4) and

the bolt (3), the spurwheel (2) and the bolt (l),
see tig 1. Tighten the bolts according to page
500.40.
N
7
Note:check that the 011pumpcan run easilywhen the m
a
*
pump is assembled. m
a
LD
N
LD

Fig 2 Bores to b e cleaned F

S

--
--
-=a-
--
----
I*=

EGZ~Z-TZGTES
=--
0406 98.47 - ESO
 Working Card
Page 3 (3) Lubricating Oil Pump 51 5-01.OO
Edition 03H

Feeler A min. 0.1 mm

gauge max. 0.3 mm

A A

If 1 Then
l
feeler gauge 0.1-0.3 mm OK
can come into the pump

feeler gauge 0.1 mm Replace bearing bush

can not come into the ,
pump i
feeler gauge 0.35 mm Replace bearing bush
can come into the pump

1
Fig 3 Check of bearing bush

98.47- ESO 0406 ---- ---

--
e
----
-v---
=
=
E==
-

S R A T N C SETS
 Working Card
Prelubricating Pump 51 5-01.05
Page I(3)
Edition 01H

Safety precautions: Special tools:

Stopped engine Plate no ltem no Note

Shut-off starting air
Shut-off cooling water Wheel pullerfor bearing bush.
Shut-off fuel oil Compressed pin.
Shut-off cooling oil Protection cover for shaft seal.
Stopped lub. oil circul. Compressed pin for shaft seal.

(The special tools must be ordered separately

from MAN B&W Diesel N S , Holeby)
Description:

Dismounting, replacement ofthe rotary shaft seal

and assembly of prelubricating pump.
Hand tools:

Bench vice.
Spanner.
Torque spanner.
Plie: for lock ring.
So3 hammer.

Related procedure:

Man power:
Replacement and wearing parts:
working time 2-3 Hours
Capacity 1 man Plate no Item no Qty. /

Data: See plate 51504.

Data for pressure and tolerance (Page 500.35)

Data fortorque moment (Page 500.40)
Declaration ofweight (Page 500.45)

96.03 - ESOS-G 0406 - ------

--
---
--
1=-5
m
---
-----m
E==-

CWERATINC s
-
 MAN
ZJMD -
51 5-01.05 Prelubricating Pump
Working Card
Edit~on01 H Page 2 (3)

Overhauls. We advise not to change the bearing bushes. In

Overhauls for the purpose of avoiding functional
trouble are not normally necessary for the prelubri-
cating pumps, when properly used, there is very little
wear on the pump gearshaft.
connection with damages on the bearings it is normal
that also the shafts and the parts in the gear box will
bedamaged.
When ordering spare parts, do not forget to state the
factory no of the pump.

Spare Parts.
Replacement of mechanical seal.
Before any overhaul is done, please note thefollowing:
1) Disconnect ihe cable and pipe connection to
If a pump gets unusable by wear, it must be replaced. the pump.
Installation of spare parts cannot bring it back to
normal condition. 2) Remove the pump fromrheengine base frame.

It pays to keep extra pumps in stockorto have repairs
(overhauls) carried out at our repair shop.
The shaft seal needs only to be replaced in case of
leakage or after dismounting of driveshaft.The marks
from theseal do not necessarilymean that thesealing
is defective, but there is a risk of leakage after
replacement of sealing.
3) Separaie the pump and the el-motor.
4) Remove the coupling part and key (IZ),see fig
1, from the driving gearshaft (4).
5) Tighten the pump to theflange. Pressure control
valve(3)upwards.
6) Loosen screws (9) and take off the pressure
control valve (3).

Fig 1. Prelubricating Pump.

-*z
- =S-===
= m-f =- =
GENEFATW SETS
0406 96.03 - ESOS-G
 ZJMD - B&W

Working Card
Prelubricating Pump
51 5-01.05
Page 3 (3) Edition 01 H

7) Take off the gear box (2), if necessary useasoft Mounting.

hammerforseparation.
8) Remove the gear wheels from the cover (1).
Dismounting is only possible by disturbing the rotor
shaft seal and by breaking the bearing bush.
9) Remove the security ring (Il)and take off the
rotary shaft seal (16).
13) The mounting process follows in reverse order,
it is stressed that an exact cleaning works is
necessary.
Especially the sealing faces must be clean.
Tightening of screw pos. (9):

10) Press out the driving gear shaft bearing bush,

pullout the running bearing bush with the innerwheel
puller.
11) Gear box (2). Dismounting is only possible by
damaging the shaft bush. Press outtheshaftbushes.
In connection with the bearing bush, attention must be
paid to the placement of the butt joint and the
mounting depth.

12) Pressure control valve (3). The pressure control The new shaft seal cannot be pressed into the
valve can be dismounted also without dismounting protection cove; before exact mounting of the pump.
the pump.
O-ring must be changed.

96.03- ESOS-G
 ZJMD - B&W

515-01.l
0 Work~ngCard
Edit1011
0 2 ~
Lubricating Oil Filter Page 2 (3)

Please note: Never open the filter while it is in use. Note: Our filter elements are of the disposable type.
The filter to be cleaned m u s t be out of operation. Always change to new original filter.

10) Clean the filter housing and the cap.

Normal Running
11) Check the seal in the cap. Change if needed.
1) The valve is in position 2 or4, see fig 2, and the
element not in use is vented and ready to use 12) Assemble the f~lterin reverse order.
(standby).
13) Switch toposition2or4andventtheexchanged
element by means of the vent screw.
Changing the Filter

2) Switch to position 3, fig 2, and wait 5 minutes.

Then continue to position 1 or 5, fig 2.
I Vent screws l
3) Wait 2 minutes.

4) Open the vent screw on thefilter out of service.

5) Wait 20 minutes

6) Dismantle the cover.

7) Dismantle the filter housing cap.

8) Remove the inner safety element. Clean the

element with detergent. Check that it is intact.

9) Remove the outer elements Fig l Vent screws

-
98.45 ESO
 Working Card
Lubricating Oil Filter
0
515-01 .l
Page 1 (3) Edition 02H

Safety precautions Special tools

Stopped engine 1 Plate no ltem no Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Stopped lub. oil circul.
Press Blocking - Reset

Description
Hand tools
Replacement of paper filter eement(s).
Cleaning of safety filter and filter housing Open-end ring spanner, 19"
Allen key, 6 mm
Allen keyl 10 mm

Starting position

Related procedure

Manpower
Replacement and wearing parts
Working time : 1 hour
Capacity 1 man Plate no Item no Qty. 1

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.45 - ESO
 ZJMD-~~~~I MAN

Working Card
L~~bricating
Oil Filter 51 5-01 . l 0
Page 3 (3)
Edition 02H

Pos.

Fig 2 Name plate for lubricating oil filter.

98.45 - ESO 0406 ------- --

--
e
m
- - --
E-
-
-
-
--
-
CENERATINC SETS
m
 #' MAN '-
i =&W!

Working Card
Page 1 (2) Lubricating Oil, ThermostaticValve 51 5-01.20
Edition 03H

Safety precautions Special tools

B Stopped engine plate no Item no Note

k$? Shut-off starting air
Shut-off cooling water
R Shut-off fuel 011
E Stopped lub o ~clrcul
l
H Press Blocking - Reset

Description Hand tools

Inspection ofthermostat~cvalveand replacement

of elements.

Starting position

Related procedure

Manpower Replacement and wearing parts

Work~ngtime . 2 hours Plate no Item no Qtyl

Capacity 1 man
51103 146 2lE

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500 45)

98.47 - ESO
 515-01.20 Working Card
Edit~on03H
Lubricating Oil, Thermostatic Valve Page 2 (2)

Adjustment and Maintenance Check the Element

The thermostatic valve cannot be adjusted and 10) Place the element in a bucket of water -12" C
under normal working conditions maintenance is not below the nominal rating and stir the water
required. However, in some cases it is necessary to vigorously with the element for 5 minutes (the
replace the element. sliding valve should not be off its seat).

1 Next. place the element in w a t e r

10" Cabove thenominal rating andstirvigorously
for 5 minutes. The element should not be fully
stroked.

This is determined by immediately placing the ele-

ment back in the vaive housing, and pushing the
element spider fully into its counterbore. If the
resistance of the s!iding valve overirave spring can
be felt, the element is fully stroked. Perform the last
step quickly before the element has cooled.

Bolt Note: do not use oil as the test bath.

Cover
Lock ring On every high tempersiure elements, water and
glycol may be used.
Element
5 Sleeve

Fig l Lubricating oil thermostatic valve.

Replacement of the Element

l) Unscrewthe bolts (1)and remove the cover (2),

see fig l

2) Remove the lock ring (3).

3) Remove the sleeve and element (4 and 5).

4) Thoroughly clean the sleeve (5).

5) Replace it or check, see "check the element".

6) Remount the element (4) by wriggling it some-

what over side.

7) Mount the sleeve (5)

8) Mount the lock ring (3).

9) Renew the gasket and mount the cover (2).

Tighten the bolt (1) according topage 500.40. Fig 2 Placing of lubricating oil thermostatic valve.

-- - - - - -
r r--=
-
-
m v --v
G
t
-
=---
-
l
WO6 98.47 -ESO
GSWERATING SETS
 Working Card
Page 1 (2) Check of Lubricating Oil Piping System 1 515-01.90
Edition 02H
1

1 Safety precautions 1 Special tools

l
Stopped engine I Plate no Item no Note
Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Stopped lub. oil circul.
Press Blocking - Reset

Description Hand tools

Check andexamination of the lubricating oii piping

system.

Starting p o s i t i o n

Engine is running.

Related procedure

Replacement a n d wearing p a r t s

Working time : l/z hour Plate no Item no Qty /

Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.41 - ESO 0406 --- ---

-- -- F-=-

E&-Gz-~Kz?es
 ZJMD - B&W

51 5-01.90 Check of Lubricating Oil Piping System Working Card

Page 2 (2)
Edition 02H

Checks to be Carried Out

l)Examine the external connections for leaks.

2) Retighten all bolts and nuts in the external

system

3) Check flexible oil vapour discharge hose con-

nections for leaks and damages.

Note: It is important that the flexible connections are

free from paint and grease and in healthy condition.

Concern'ng 1ubricat;ngoil condition: see section 554.

--
--
c r-r ---=
RE-
=GENERATPUG
m-=-~= C406
-
98.41 ESO
SETS
 Working Card 51 5-06.00
Page 1 (5) Lubricating Oil Cooler Edition 03H

Safety precautions Special tools

E Stopped engine Plate No Item No Note

Shut-off starting air
E Shut-off cooling water 52015 012
Shut-off fuel oil
H Stopped lub. oil circul.
Press Blocking - Reset

Description / Handtools
l
Separation. cleaning and assembling. Ring and open end spanner 10 mm
Replacement of plates and gaskets. Ring and open end spanner 55 mm
Ring and open end spanner 30 mm
Adjustable spanner

Starting p o s i t i o n

Cooling waterand lub. oil have been drained from

coolerlengine.Allexternal pipesaredisconnected.

Related p r o c e d u r e

Manpower Replacement and wearing p a r t s

Working time : 4 hours Plate No Item No Qty.1

Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.43 - ESO 0406 --

p =-E
--
%E=+
~BUE__Rn~T=
U
IC-
=g===
 ZJMD - B&W

51 5-06.00 Working Card

Edition 03H
Lubricating Oil Cooler Page 2 (5)

Introduction Upon completion of the procedure "Cooling and

Cleaning of the cooler must take place, when the
pressure drop on the oil and water side exceeds an
allowable value andtor if oil cannot be sufficiently
cooled.
Separation
Cooling and Pressure Relief
Before opening the plate heat exchanger, ii must be
cooled down to beIow40" and be without pressure!
Pressure Relief', separate the frame by retaining
two or four diagonally placed bolts.
Note: Take care that the pressure plate does not tilt!
Loosen the bolts uniformly and diagonally (max. 10
mm at a time), then push the pressure plate towards
the end support. When the pressure plate is not tight
anymore, the plates can be removed.
Note: When using plate heat exchangers on board
ships, the pressure plate must be secured in order
to avoid danger during the movements of the ship.

The cooling must not exceed 10" C per minute.

The pressure drop must not exceed 10 bar per
minute.
Note: If these norms are exceeded, the guarantee
will cease to be valid.
Cleaning
The capacity and corrosion resistance of the plate
heat exchangers depend on the cleanness of the
plates. Any coating on the plates can be removed
manually.

Separation of Edge-clamped Frame

Manual Cleaning
Mount the bolts, see fig. 1.
Clean the plates with a soft brush and a suitable
detergent. In the case of dense coating of scale or
organic materials, the plates must be put in a bath
with detergent

Note: Never use a steel brush, metal scraper orthe

like.

A high-pressure cleaner can be used with care,

however, never with sand or other abrasives added.

Detergents

A detergent is suitable, if it removes any coating on

the plates without causing any damage to plates and W
gaskets. 7

m
9
P

I I Note: It is of great importance that decomposition of

the protective film on the stainless steel does not 2
Fig 1 Mounting of oil cooler in front-end box. S
take place - the film preserves the corrosion resis- 0
?
tance of steel. m
N
0
m
0

Do not use chlorine-containing agents such as

hydrochloricacid (HCI)!

ESO
 ;' M A N '\
ZJMD - IB&W L B&W 5

Working Card
Lubricating Oil Cooler 51 5-06.00
Page 3 (5) Edition 03H

Oil and fats are removed by using a water ernulsify- Replacement o f P l a t e s a n d G a s k e t s

ing oil solvent, e.g. BP-system cleaner.
Marking
Organic and greasy coatings are removed by using
sodium hydroxide (NaOH): The plates are marked with material codes and
reference numbers at each end, plus codes for non-
- rnax. concentration 1.5% glued gaskets, if any, and stamped with letters V
(1.5% concentration corresponds to 3.75 1 and H at either end (fig I).
30% NaOH per 100 1 water).
- rnax. temperature 85= C. When facing the gasket, the plate is designated as a
left plate, when IetterV turns upwards - and as a right
Stone and Iime/calcareous deposits are removed by plate when IetterH turns upwards. Inlets and outlets
using nitric acid (HNO,): of the V-plates are taking place through the corner
holes Nos 1 and 4. Inlets and outlets of the H-plates
- max. concentration 1.5% take place through corner holes Nos 2 and 3.
(1.5% concentration corresponds to 1.75 1
62% HNO, per l 0 0 I water).
- rnax. temperature 65%. Replacement o f P l a t e s

Note: The nitric acid has an important constructive Before mounting a spare plate in the plate stack,
effect on the protective film of stainless steel. please make sure that the spare plate is identical
with the faulty one.

C o n t r o l of C l e a n i n g Fluid C o n c e n t r a t i o n s Note: The same corner holes must be opened and

letters V and H must be placed properly.
Sodium hydroxide (NaOH) solution is titrated with
0.1 n hydro-chloric acid (HCI) with methyl orange or
methyl red as an indicator. Replacement o f G l u e d Gaskets

Nitric acid (HNO,) solution is titrated with 0.1 n On Plate 51506 stated are gasket and glue quantity.
sodium hydroxide (NaOH) with phenolphtalin as an
indicator. Please use a degreasing agent on the new gaskets.

The concentration of the cleaning fluid in % can be The first plate after the end cover and the connector
calculated from the titration result with of the follow- grid must have gaskets in all grooves. The gaskets
ing formula: must be cut according to the existing gaskets.

Concentration = bxnxm % Loosen the glued gaskets by heating the plate in

axlO water at 100" C. Clean the plates and remove the
coatings, if any.
a : m1 cleaning fluid taken out for titration
b : ml titration fluid used as a cover
N

ro n : the molecular concentration of titration fluid

9
P m : The molecular weight of the cleaning fluid
S
L0
(NaOH) the molecular weight 40, H N 0 3
N
In rnolecularweight63)
r
2
4
m
N
0
m
0

ESO
 515-06.00 Lubricating Oil Cooler Working Card
Edition 03H Page 4 (5)

C l e a n i n g of New G a s k e t s and Plates
New gaskets and gasket grooves of the plates are
cleaned with a cloth moistened with degreasing
agent. The glued surfaces must be absolutelyclean
- without finger prints etc.
Please use our cleaning fluid, which conforms to
suppliers recommendations.
The plates with the gaskets are mounted in the frame
which is lightlyclamped. In the case of using rubber
grooves, they are assembled to the minimum mea-
sure stated on the engine sign plus 0.2 m m per plate.
Heat up the plate heat exchanger to 90-100" C by
means of water or steam.
Please note:

Alternatively, please use: - The temperature must be kept for 1 112-2

hours.
- Trichloroethylene - The liquid pressure must be kept as low as
- Chlorothene VG possible.
- Acetone
- Methyl ethyl ketone l! there is no possibility of heating the plate heat
- Ethylacetat exchanger, it must be placed in a place as warm as
possible with connections dismounted.
It is important that all degreasing agent be evapo-
rated, before glue is applied. This will normally take At 20" C the drying time will be approx. 48 hours.At
approx. 15 min. at 20" C. 40" C, the drying time is approx. 24 hours.

Clean the new gaskets on the glued surfaces with

fine-grained sandpaper instead of the degreasing Assembling
agent supplied.
If the plates are dismounted, they must be properly
assembled according to plate item numbers.
Gluing
The fixed cover has number 1 and serial numbersfor
Pliobond 25, which is a solvent-based nitrile rubber the subsequent plates, and intermediate frames, if
glue (25% solids). The glue is applied with a brush any?are numbered 2, 3, 4, 5 etc.
in a thin layer on the backs of the gaskets and the
gaskets must be dried in a clean place free of dust.
Serial number
(please state when
Apply a thin layer of glue on the gasket grooves of
the plates and press the gaskets down into the
gasket grooves.

The insertion ofthe gaskets starts at both ends of the

plate- and continues with the straight sections along
the edges.

The gluing process is most easily performed by

placing the gaskets and the plates on a table. After
pressing the gaskets into the grooves of the plate, Four last digits Four last digits are ref.
it is stacked. are ref. number H numberoftheplate.(only
Or on plates for non-glued
ofplate
gasket)

Fig 2 Plate with serial no etc.

--
= -
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=
-
-
E
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=
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-
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=-
98.43 - ESO
C M R A T I U G SETS
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ZJ M D - B&W f =&W'

Working Card 51 5-06.00

Page 5 (5)
Lubricating Oil Cooler Edition 03H

Serial numbers are stamped in the right top corner of Fastening

the plates. Further, please note that the gasket side
must face the fixed cover. Fasten the nutscrosswise untll the movable cover to
the measure X at each nut.

l l

Fig 3 Measuring X

98.43 - ESO 0406

-- --- -----
-
---
-v- ----
-- -- L

GE'JERATINC SETS
 Working Card
Centrifugal Bypass Filter
51 5-15.00
Page 1 (3)
Edition 03H

Safety precautions Special tools

Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cooling water
[? Shut-off fuel oil
Stopped lub. oil circul.
[? Press Blocking - Reset

I Description
l Hand tools

Cleaning procedure, cleaning intervals. Big adjustable spanner

Maintenance intervals and procedures. Tools for cleaning.

Starting position

With the enginestopped orfilterisolated by means

of a valve.

Related p r o c e d u r e

Replacement a n d wearing p a r t s

Plate no Item no Qtyl

.-
N

m
Capacity 1 man
9

1
P
m
0'
m
m
N Data
F
6
? Data for pressure and tolerance (Page 500.35)
m
N
m
0 Data for torque moment (Page 500.40)
m
Declaration of weight (Page 500.45)

98.47 - ESO 0406

---- ---
=
-
m-- - - --
A

m m----
-p---

CWERATffi SETS
 ZJMD - B&W

51 5-15.00 Centrifugal Bypass Filter Working Card

Edition 03H Page 2 (3 )

Cleaning Procedure 5) Remove stand tube (075) and clean

6) Remove sludge from inside the rotor by means

l) Isolate the filterby closing the valve forlubrica-
tirlg oil inlet to the filter.
2) Slacken covercamp ring (266). Unscrew cover
fixing nut and lift off cover.
3) Liftoff rotor assembly having allowed oil todrain
from nozzles. The rotor should be removed and
replaced on the spindle with extreme care in
order to ensure that the bearings are not
damaged.
4) Unscrew rotor cover nut (026) and separate
cover (038) from body.
ofaspatula and wipe clean. Ensure that all rotor
components are throughly cleaned and free
from deposits of dirt before reassembling the
rotor.
Note: Failure to do s o could cause an out-of-
balance condition which will accelerate bearing
and spindle wear.
7) Clean nozzle with brass wire. Examine top and
bottom bearings in tube assembly. If damaged
or worn - replace tube assembly complete.
'
Examine O-ring and renew if damaged.
8) Replace paper insert (if mounted).

9) Reassemble rotorcompleteand tighten topnut.

Note: Ensure that rotor cover and rotor body are

always matched by balance numberand pin location.
Do not interchange rotor cover.

10) Examine spindle journals. If damaged or worn

- replace with body assembly complete.

l ) ' Reassemble filtercomplete checking that rotor

revolves freely. Then replace filter body cover
Tighten covernut and secure safety clamp. The
'
clamp ring should be securelyfitted at all times
and the filtershould not be run withouttheclamp
ring fitted.

12) Open for lubricating oil.

1 13) With filter running check all joints for leakage.

Check for excessive vibration.
026 Cover nut
038 Cover
075 Stand tube
266 Cover clamp ring Maintenance - Bearings and Spindle

All rotors are correctly balanced before leaving the

Fig 1 Centrifugal bypass filter factory. An out-of-balance condition can occur as a
result of an uneven build up ofsludge in the rotor oras
a result of excessive bearing or spindle wear.

Dependent on the conditions, wear will eventually

take place on the spindle and bearings and these
should be replaced with factory fitted assemblies
only.

98.47 - ESO
 Working Card 51 5-15.00
Page 3 (3 ) Centrifugal Bypass Filter Edition O ~ H

TO Check Bearing C l e a r a n c e s Spindle top journal diameter 14.98 mm Min.

Spindle bottomjournal diameter 21.63 mm Min.
This is most easily done by applying a dial gauge to Top bearing borediameter 15.06 mm Max.
the outside of the rotor opposite each bearing in turn Bottom bearing bore diameter 21.69 mm Max.
and measuring the total play thus:
Thespindle and body assemblyand the rotor bearing
14) Apply dial gauge and measure play. tube assembly are factory assembled items and
should only be replaced with complete assemblies.
15) Turn rotor 90" and repeat measurement.

16) Re-apply dial gauge at 90" to previous position

and repeat.

17) Turn rotor 90" and repeat.

'The highest reading is the play in the bearing.

The maximum clearances when new are 0.08 mm at

top and 0.06 mm at bottom bearing. If the clearance
exceeds 0.25 mm top or 0.2 mm bottom then check
the sizesofthe individual components and replace as
necessary.

98.47- ESO m
- - -- -
-
-- ---
--
--
Ir t o

C-Tffi
,
- - W

SETS
 ZJMD - E&W

Plate
Page 1 (2) Lubricating Oil Pump 1 51501 -06H /

l
98.48 - ESO a406 =
---
-- - ----
- - --=S-
--
- - -z
-

~ - ~ ~
 ZJMD - B&W

Plate
51501 -06H Lubricating Oil Pump Page 2 (2)

m
o: ' 1 Qty 1l Designation Designation Benzvnelse
l l

1/E Lubricating oil pump, Smoreoliepumpe, korn-

comp. 5-6 cyl. engine
incl. item 018,055,067,
079,092,102,114,126,
, 151,175,187,199
l
1IE i Lubricating oil pump,
plel 5-6 cyl motor
incl.item 018,055,067,
079,092,102,114,126,
151,175, 187, 199
Smoreoliepumpe, kom-

1i
comp. 7-9 cyl. engine
incl. item 018,055,067,
080,092,102,114,138,
plet 7-9 cyl. motor
inkl. item 018,055, 067,
080.092,102,114,138,
i163,175,187,199 163,175,187,199

3lP

61P
' Cylindrical p ~ n
, Screw
Cyrndrisk st~ft

Skrun
I
llP / Pump housing P~~rpei-us i
/ complete incl item konplet ~rl<l~ t e r
1 102,126,151 1C2 126 151
15-6 cyl. engine 5-6 cyl motor I

1/P
l Pump housing,
complete ind. item
102,138,163
Pumpehus,
komplet ink1 item
102,138,163
7-9 cyl. engine 7-9 cyl. motor

092 / 1/P Cover D~ksel 1 1

i
4 1 ~1 ~ u s h Bssning

6/P /Screw Skrue

1/P
1 Gear wheel,
5-6 cyl. engine
Tandhjul,
5-6 cyl. motor

Tandhjul,
7-9 cyl. engine 7-9 cyl. motor
l
1 Gear wheel, Tandhjul,
15-6 cyl. engine 5-6 cyl. motor
l
Gear wheel, Tand hjul,
7-9 cyl. engine 7-9 cyl. motor
I Cylindrical gearwheel Cylindrisk tandhjul

Washer Skive

Screw Skrue

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se o g s l side 500.50.
= Only available as part o f a spare parts kit. = Kun tilgzngelig sorn en del af et resewedelss~t
QtylE = QtylEngine Qty/E = QtylMotor
QtylP = QtylPump QtyIP = QtylPumpe

98.48 - ESO
 ZJMD --fsaw\
MAN

Plate
Page 1 (2) Lubricating Oil Filter 51 502-04H

99.06 - ESO 0406 - ----

--
--
L
----
- - --
E--=
m
-
G

CWERATNC SEE
=-
=
 ZJMD - S&W

Plate
51502-04H Lubricating Oil Filter Page 2 (2)

Item
Qty Designation Benawnelse no Designation Ben~vnelse
-
61E

2/E
ll Filter cartridge

Cover
Filterindsats

Dzksel
300

312
Lever

Latch pin
Arm

Lssestift

81E Screw Skrue Spring pin Fjederstift

61E 0-ring 0-ring

21E Cover, complete incl. D ~ k s e l kornplet

, inkl.
item 216 ~tem216

21E Safety filter Sikkerhedsfilter

/1
Afstandsring
Spaser ring
Cover, complete D ~ k s e lkornplet
,

l Screw
Skrue

Covering, complete Skzerm for ds?ksel.

Incl. item 228,241,253 komplet inkl. item 228,
241.253

Screw Skrue

l Shaft Aksel

/ Shaft Aksel

0-ring 0-ring

Cylindrical pin Cylindrisk stift

1/E

21E
I Plate

0-ring
Plade

0-ring

11E Plate Plade

61E Screw Skrue

2E Guide ring Styrering

2/E Cover Sk~rm

2/E Screw S k ~ e

2/E Retaining ring Sikringsring

2,E Filterguidewithsafety Filterstyr med sikker-

valve hedsventil

ZE Spring Fjeder

2/E Screw Skrue

2E Distance piece Afstandsstykke

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsa side 500.50.

= Only available as part o f a spare parts kit. = Kun tilgzengelig sorn en del af et reservedelsszt.
QtylE = QtylEngine QtylE = QtylMotor

l ===S
z--T=.&y&
--
0406 99.06 - ESO
 Plate
Page 1 (2) Prelubricating Pump with El-Motor

94.23- ESOS-L 0406 , , ,= -*

GENRAW5Fl5
 ZJMD - B&W
-
Plate
51504-02H Prelubricating Pump with El-Motor Page 2 (2)

hem hem
No. Qty. Designation Benaevnelse No. Qty. Designation Benaevnelse

254 1/P Driving cover Medbringerdzksel

266 1/P Gear casing Gearhus

278 1/P End cover, complete, Endedatksel, komplet

incl. item 386,398,408, inkl. item 386,398,408,
421,433,445,457,469 421,433,445,457,469
and 470 og 470

291 1 1 l/P Driving gear shaft Drivende gearaksel

I !
301 1 I 1IP Gearshaft Gearaksel
l l
313 / 1 4/P Screw Skrue

325 ( 2/P 1 Parallel pin Styrestift

l I
337 1/P Retaining ring Sikringsring

349 11P Parallel key Not

350 ( ZIP / 0-ring 0-ring

l I
362 l lip
, Rotary shaft seal Roterende akseltzf-
nlng l I
l I
l

374 liE Pumpe, complete Pump. komple: uae?

without E l m o t o r e-motor

386 1 1IP 1 End cover Endede~sel I

398 1IP Piston Sternpel

408 1/P Spindle Spindel

421 1/P Dome nut Lukkemprtrik

433 1/P Spring Fjeder

445 1/P Pipe nut Rvrmvtrik

457 ZIP Screwed plug Propskrve

469 ZIP Sealing ring Tztningsring

470 2/P Sealing ring Tztningsring

482 1 1 lP Coupling, complete Kobling, komplet

494 / / lE El-motor, complete El-motor, komplet

Pre.lub oil pump, Forsmprrepumpe,

complete with el- komplet med el-motor

516 / l/E I Ball bearing, rear Kugleleje. bagside

528 ( l/E I Ball bearing,front Kugleleje, forside

m
N
m
0
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se o g s i side 500.50. o

= Only available as part o f a spare parts kit. * = Kun tilgzngelig sorn en del af et reservedelsszt.
L Qty.lE = QtyJEngine AntallE = AntallMotor
Qty.lP = Qty.lPump Antal/P = Antal/Purnpe

--
-.-m--
*-*
G E N E R A W SEE
0406
94.23 - ESOS-L
 ZJMD - B&W

Plate
Page 1 (2) Lubricating Oil Cooler 51506-03H

98.12 - ESO 0406 - ----

--
---- --
- - --
I= A t E=-
--
-
CENERATWG SETS
 Plate
51506-03H Lubricating Oil Cooler Page 2 (2)

Qty
!
/ Designation Benaevnelse Qty 1 Designation Benavnelse

1/K Plate Plade

l

14/K l Screw l Skrue

l
4/K / O-ring, oval O-ring, oval

8/K j Screw Skrue

I/K plug screw Propskrue

1

1/K 1 Packing ring Pakningsring

1X 1l Plate Plade

1/K 1 Plate Plade

l
10/K Self locking nut
l
Selvlisende rnstrrk
I
l
10/K Washer Sk~ve
1
10/K Screw
l
' Skrue

/I 1 Gasket Paknirg

1 / Plate
160

l72 / /l

l/E 1
Plade

Lubricatingoil cooler, Smsreolieksler,

1 5 cyl. engine 5 c$, motor

Lubricating oil cooler, Smsreolieksler,

6 cyl. engine 6 cyl. motor

lg6 I i 1/E Lubricating oil cooler,

7 cyl. engine
Smsreolieksler,
7 cyl. motor

206
1/E

I I Lubricating oil cooler, Smsreolieksler,

8 cyl. engine 8 cyl. motor

Lubricating oil cooler, Smsreol~ek~ler,

9 cyl. engine 9 cyl. motor

Lim
I l

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsi side 500.50.
= Only available as part o f a spare parts kit. = Kun tilgzngelig som en del af et resewedelssEet.
QtylE = QtylEngine Qty/E = QtylMotor
QtylK = QtylCooler Qty/K = Qty/Ksler
Qtyll = Qtyllndividual Qty/l = Qtyllndividuelt

98.1 2 - ESO
 \ I--

CL *-=*-
'i

%kZt;,
[MAN .,
ZJMD- LS&W i

Plate
Page I(2) Centrifugal By-pass Filter 51515-02H

97.47 - ESO 0406 --

--- ---
= * --- -p-=---

?~~-E~T?$cTE
 Plate
51 51 5-02H Centrifugal By-pass Filter Page 2 (2)

ltem ltem
No Qty Designation Benavnelse No ( Qty Designation Benavnelse
! i
014 1/F Body , complete incl. Sokkel, komplet ink1 301 1/F Cover nut fixing kit, Dskselmertrikskil, inde-
item 026,038,051,063, ~tem026,038,051,063, consisting of item 134, holdende item 134,146,
075,087,099,109 075,087,099,109 146, 158,171 158,171
l
026 1/F j ~ a l v ebody Venblsokkel Valve kit,consistingof Ventikit, indeholdende

038 1 1lF V a l v e handle VentrlhOndtag

item 026,038,051,063, item 026,038,051,063,
075,087 075,087
l Nyloc nut
051

063
1/F

1/F ,Valve adaptor

Motrik

Ventrladapter
325

j
1/F
1Seals k i t consistingof Tztningskit, indehold-
item 087,099,109,118, endei:em087.099,109,
(242 158 242

075 1 1/F j Valve stop Ventiistop 337 1 1/E ( Centrifugal by-pass fil- Centrifugal by-pass fil-
I i ter, komplet som vist p i
087 1 l i F Valve seal j Ventilt~tning
ter, complete as
shown on front page fors~den

099 1 l
i
1IF Flange gasket Flangepakning

109 ( 11F / Filter body 0-ring Filtersokkel 0-ring

I
110 1/F 'Cover, complete incl. Dzksel, komplet inkl.
(item122,134,146,158, item 122,134,146,158,
j 171 171

122 IlF Cover Dzksel I

!
134 11F 1 Cover nut pin Stift for dzkselmotrik

146 l / F C o v e r firing nut Dzkselmotrik

158 liF Cover nut 0-ring Dskselrnertrik 0-ring

171 ( l / F c o v e r nut collar

183 1I 1IF / B a n d clamp Spendering

1 Rotor, complete incl. Rotor, kompletinkl. item

item 205,217,229,230, 205,217,229,230,242,
242,254,266,278,291 254,266,278,291

Nozzle Dyse

I
l
Bearing tube Lejerlar

l Stand tube Standrerr

230 1/F ' Circlip LBsering

242 1IF Rotor 0-ring Rotor 0-ring

254 11F Pin Stift

266 1/F Rotor cover nut Rotordzkselmertrik

278 1/F Paper insert Papirindsats

291 ( IIF l Stiffnerplate Plade

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs6 side 500.50.
= Only available as part of a spare parts kit. = Kun tilgengelig som en del af et reservedelsset.
~ ~ QtyIE = QtyIEngine QtylE = QtyIMotor
QtylF = QtylFilter QtylF = QtyiFilter

97.47 - ESO
 % MAN '.
: B&W

Plate
Page I( 2 ) Lubricating Oil Separator 51530-02H

99.06- ESO 0406

-
--
- p
---
E-
-=
-
-
=
- - -

EG~F~KTFG~E?~
 &:$3Yz::2,,p*
j i - &
:
d' \\;

Plate
51530-02H Lubricating Oil Separator Page 2 (2)

Item
No Qty Designation Benzvnelse Qty (Designation Benawnelse

016 1 l / E / P l u g screw Propskrue 1

028 1 / l/E Packing ring Pakningsring

041 1 l 4/E Nut Motrik

065 1 l 4/E Washer Skive

077
089
l l
1 1 2/E
*IEScrew
Screw
Skrue

Skrue

( Bow Baj~i~g
l
/ cover Dz~sel

i Screw Skrue

/ Pakning

( Housing Hus

Lubricating oil sepa- Srn0reolieseparator,

rator, c o m p l e t e as kornpletsornvistp8for-
shown on front page siden

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsb side 500.50.

- = Only available as part of a spare parts kit. = Kun tilgangelig sorn en del af et reservedelssat.
QtyJE = QtyJEngine Qty.iE = Qty.lMotor

99.06 - ESO
 Plate
Page I (2) Prelu bricating Oil Arrangement 51535-02H

Prelub. oil pump, 204

see plate 51504

00.14 - ESO 0406 ---

--
=i=
--v---
-- -
+&-E
ENERATNC SETS
 Plate
51 535-02H Prelubricating Oil Arrangement Page 2 (2)

m
o: ' / 1
Qty Designation Benrevnelse I
~ t yDesignation
l
Bensvnelse

/1 I
1IE Adjustable straight Justerbar
male stud coupling ligeforskruning
OS7
049 1lE /Male stud coupling Vinkelforskruning

050 I l l E /Ball valve Kugleventil

062
074
1 I 11E

1IE
Straight male
stud coupling

Equal tee coupling,

complete
Ligeforskruning

T-forskruning,
kornplet

086 1IE Pipe Ror

098 1 21E l ~ d j u s t a b l eelbow Justerbar vinkel

108 11E Non-return valve Kontraventil

121 11E Reducing adaptor Reduktionsadapter

133 / 1 1IE Non-return valve Kontaventil

145 1 21E ( ~ h r e a d e sleeve

d Bprsning

157 11E Packing ring Pakningsnng

169 11E Bleeding screw Skrue

170 11E Pipe Rprr

182 1 l/E (Pipe Rar

194 / 1 llE Pipe Ro:

Skxe

i
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs5 side 500.50.

1 - = Only available as part of a spare parts kit.

Qty/E = QtylEngine QtyIE
=
=
Kun tilgaengelig som en del af et reservedelsstet.
QtylMotor

00.14 - ESO
 Cooling Water System

, P---

;Internal coolina water svstem 1516.01C04H) j

i
l!Check of cooling water system
-
1 5 1 6 - 0 1 . 9(Q2H)
~ !
ICooling water, thermostatic valve 1516-04.00( 6 2 3 ) j

/HT and LT water pumps i516-10.0@{ O l F t )

'Hiqh and loii t e r n ~ e - x u r efresh water uurnus 15 k610-03~

 MAN ;,
ZJMD - E&W g B&W i

Description 51 6.01
Page 1 (1) Internal Cooling Water System Edition O ~ H

Cooling Water System

The cooling water system consists of a low tempe-

rature system and a high temperature system.

Both the low and the high temperature systems are

cooled by treated water.

The water in the low temperature system passes

through the low temperature circulating pump which
drives the water through the second stage of the
charge air cooler and then through the lubricating oil
cooler before it leaves the engine together with the
high temperature water.

The high temperature cooling water system

passes through the high temperature circulating
pump and then through thefirst stage ofthe charge air
coolerbefore it enters the cooling waterjacketand the
cylinder head. Then the water leaves the engine with
the low temperaturewater.

Both the low and high temperature water leaves the

engine through separate three-way thermostatic
valves which control the water temperature.

It should be noted that there is no waterin the engine

frame.
Fig 1 Integral cooling water system.

Thermostatic Valves

The thermostatic valves are fully automatic three-

way valves with thermostatic elements set at fixed
temperatures.

99.03 - ESO 0406

- - ----
- - v
m
- ---
---
E-C C--5
c_--

GENERATNO SETS
 Working Card
Page I ( 2 ) Check of Cooling Water System 516-01.90
Edition 02H

Safety precautions Special tools

@ Stoppedengine Plate no Item no Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Stopped lub. oil circul.
Press Blocking - Reset

Description Hand tools

Check of cooling water system.

Starting p o s i t i o n

1 Engine is running.

/ Related procedure

Manpower Replacement a n d wearing p a r t s

Working time : % hour Plate no Item no Qty.1

Capacity 1 man

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.41 - ESO 0406 =

--
--
-- -- - - -
S
---
==-=

EE-k-GiiScYes
51 6-01.90 Check of Cooling Water System Working Card
Edition 02H Page 2 (2)

Checks to be Carried Out
l) Examine the cooling water connections for
leaks.
2) Check flexible connections for leaks.
It is importanf fhaf fhe flexible connections are free
from painf and grease and in healfhycondifion.
4) Check the condition ofthe outermost ofthe two
0-rings (which makeupthe tightening between
the waterjacket and the combustion space) b y
means of the inspection holes in the cylinder
cover.
Concerning check of the fresh water condition, see
section 504.

3) Check 0-rings in water connections between

cylinder covers and also between cylinder
covers and front-end box.

98.41 - ESO
 i-" M A N ':
ZJMD - B&W i B&W:

Working Card
Cooling Water, Thermostatic Valve
51 6-04.00
Page 1 (2) Edition 02H

Safety precautions Special tools

a Stopped englne Plate No ltem No Note

a Shut-off start~ngalr
E l Shut-off cool~ngwater
Shut-off fuel or1
Stopped lub. 011c~rcul.
a Press Blocking - Reset

Description Hand tools

Inspection of thermostatic valve and replacement

of elements.

Starting p o s i t i o n

Cooling waterdrainedfrom engine (if necessary).

Related p r o c e d u r e

Manpower Replacement and wearing parts

Working time : 2 hours Plate No ltem No Qtyl

Capacity 1 man

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.41 - ESO 0406 - ---

--
---
'"E
- - --
m----

-RATING
E=-
--

SETS
516-04.00 Cooling Water, Thermostatic Valve Working Card
Edition 02H Page 2 (2)

The thermostatic valves cannot be adjusted and 5) Remount a new element (4) by wriggling it
under normal conditions maintenance is not re- somewhat over side.
quired. However, in some cases it is necessary to
clean or replace elements. 6) Mount lock ring (2) in the recees.

7) Clean the sealing surface ofthecasing. Tighten

Replacement of Elements bolts according to page 500.40.

l ) Remove the casing by unscrewing bolts ( l ) ,

see fig I .

2) Remove lock ring (2)

3) Remove element (4) from the casing.

4) Thoroughly clean sleeve (3).

F i j 2 Seen from front end of the engine.

Bolt
LOCKring
Sleeve
4 Element

Fig l Cooling water thermostatic valve.

98.41 - ESO
 ZJMD - B&W

Working Card 51 6-10.00

Page I(2) HT and LT Water Pumps Edition 01 H

Safety precautions Special tools

.... stopped engine Plate No Item IN0 Note

Shut-off starting air
Shut-off cooling water
D Shut-off fuel oil
E Stopped lub. oil circul.
E Press Blocking - Reset

Description Hand tools

/I Disassembly, overhaul and assembly of HT and

LT pumps
(

Starting position

Related procedure

Manpower Replacement and wearing parts

Working time : 1 hours Plate No Item No Qty I
Capacity 1 man

Data
Data for pressure and tolerance (Page 500.35)
Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

98.41 - ESO
516-10.00 Working Card
Edition 01 H
HT and LT Water Pumps Page 2 (2)

Afterthe cooling waterthermostat casing is removed I n s p e c t i o n o f the Pump

the cooling water pumps can be dismounted.
6) Inspect the shaft for seizures after removing
1) Remove the screws ( l ) , see fig. l and pull out the shaft seal and bearings, also inspect the
the pump by means of the spring bolts. impeller for pittings and caviations. Clean all
parts carefully.

Assembling o f t h e Pump

7) Fit new bearings (13) and (14) together with a

new shaft seal (15).

8) Mount the shat; In the housing and lock it with

the lock ring (11).

9) Fit the spur wheel (4) and washer (3) with the
screw (2) and tight it according topage 500.40.

10) Fit carefully the slide ring joint (10), then fit the
washer(8) and the impeller(9) and tightthe nut
(7) according to page 500.40.
I 1
2
Casing
Screw
Lock ring
Shaft
11) Mount the cover (6) with the screw (5) and tight
3 Washer Ball bearing
them according to page 500.40.
4 Spur wheel Lock ring
5 Screw Shatt seal
12) Fit new o-rings on the pump housingand pump
6 Cover Thrust washer cover, then mount the pump in the front end
7 Nut Bai! bearing box with the screws ( l ) , see fig. 1 and tight
8 Disc 0-ring them according to page 500.40.
9 lmpelier 0-ring
10 Slide ring joint

HT water pump LT water pump

Fig 1 HT and LT water pumps
'.

Disassembling of the Pump

2 ) Remove the screw (2), see fig2and pull of the

washer (3) and spur wheel (4).

3) Remove the bolt (5) and the cover (6).

4) Remove the nut (7) with disc (g), then remove

impeller (9) and the slide ring joint (10).

5 ) Take out the lock ring (1 l ) , then pull out the

shaft (12) with bearings (13) and (14) and the
shaft seal (15).

Fig 1 HTand LT water pumps

98.41 - ESO
 ZJMD- B&W

Plate
Page 1 (2) High- and Low Temperature Freshwater Pumps

97.51- ESO 0406 ---

S
----
-----
--
G-TPUC
---
-S=-=

SETS
 Plate
51 610-03H High- and Low Temperature Freshwater Pumps Page 2 (2)

l Qty 1 Designation Qty Designation Benzevnelse

Radialkugleleje
bearing

1/P
l Ball bearing Kugleleje

1i
1/P Retaining ring Sikringsring

1/P Retaining ring Sikringsring

1/P Shaft seal Pakdise

1/P

2/E
l Slide ring joint

Freshwater pump,
Roterende pakning

Ferskvandspumpe,
l
complete as shown komplet som vist
on front page p i forside

4/P
I Screw Skrue

1/P

1/P
l Pump housing

lmpeller
Purnpehus

L~behjul
l
1/P Cover Dzksel

41P Screw Skrue

4/P Lock washer

1/P Shaft Akssl

Self locking nut Se'vllsende rnatr~k

Disc Skive

Spur gear Cylindrisk tar,dbj'~,

Washer Skive

Screw Skrue

Loctite Loctite

O-ring O-ring

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsi side 500.50.
= Only available as part o f a spare parts kit. = Kun tilgzngelig sorn en del af et reservedelsszet.
QtylE = QtyIEngine QtylE = QtyIMotor
Qty.lP = Qty.lPurnp Qty.lP = Qty./Purnpe
Qty.n = Qty.llndividua1 Qty.11 = Qty./lndividuelt

E
-- _
--- =*= -
W ==
_ _-
- --
&-

GENERATING SETS
97.51 - ESO
 MAN
ZJMD-(B=W\

Plate
Page 1 (2) Cooling Water Connections 51630-02H

98.45 - ESO 0406 - =A-

-
-----
p
-=--8
- -

CENERATNG SETS
- -
 ZJMD - E&W
-
Plate
51630-02H Cooling Water Connections Page 2 (2)

Item
no Qty Designation Benavnelse Designation Benavnelse

021 1 1
21E Flange Flange
I
Seal ring T~tningsring
5 cyl. engine 5 cyl. motor
6 cyl. engine 6 cyl. motor
7 cyl. engine 7 cyl. motor
8 cyl. engine 8 cyl. motor
9 cyl. engine 9 cyl. motor

Screw Skrue
5 cyl. engine 5 cyl. motor
6 cyl, engine 6 cyl motor
7 cyl. engine 7 cyl, motor
8 cyl. engine 8 cyi. motor
9 cyl. engine O cy:. motor
Lock washer Lbseskive
5 cyl. engine 5 cyl rno:o;
6 cyl. engine 6 cy: noto:
7 cyl. engine 7 cyl. motor
8 cyl, engine 8 cyl. motor
9 cyl. engine 9 cyl. motor

Intermediate piece Mellernstykke

Safety clamp Sikkerhedsring

Stud Tap

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se o g s i side 500.50.
= Only available as part o f a spare parts kit. = Kun tilgzngelig som en del af et reservedelsszt
- QtylE = QtyIEngine
QtylC = QtylCylinder
QtylE
QtylC
=
=
QtylMotor
QtyICylinder

98.45 - ESO
Indexpage
1 (1) Special Equipment 517
 MAN
ZJMD -fBEkw\

Alternator
 Indexpage
1 (1)
Specific Plant Information 519

I
IResil~entmountrnq o f qeneratins sets

l ~ l t t i n ginstructron for resilrent mounting of GenSets '519-03.63( 2 4 )

i ~ i t t n~ snt r~u i r o n for resrl~entm o u n t ~ n gof GenSets;519-03.00 ( 2 5 )

i ~ ~ t ~nstructron
t ~ n ~ for r e s ~ i e n mountrnq
t of ~ e n ~ e:519-03.06
ts (26)

l 1
iFlexible external connections 151982-04H Iil

lconrcal element i51903-O~H i1

 ZJMD - S&W

Description
Page I (2) Resilient Mounting of Generating Sets Edition O ~ H

Resilient Mounting of Generating Sets
On resiliently mounted generating sets, the diesel
engine and the alternator are placed on a common
rigid base frame mounted on the ship'slmachine
house's foundation by means of resilient supports,
Conical type.
All connectionsfrom the generating set to the external
systems should be equipped with flexible connec-
tions and pipes. Gangway etc. must not be welded to
the external part of the installation.
1) The support between the bottom flange of the
conical mounting and the foundation is made
with a loose steel shim. This steel shim is
adjusted to an exact measurement (min. 75
mm) for each conical mounting.
2) The support can also be made by means of two
steel shims, at the top a loose steel shim of at
least 75 mm and below a steel shim of at least
10 mm which are adjusted for each conical
mounting and then welded to the foundation.

Resilient Support
I Method 1

Aresilient mounting ofthe generating set is madewith

a number of conical mountings. The number and the
distance between them depend on the size of the
plant. These conical mountings are bolted to the top
flange of the base frame (see fig I). S!ee shi

The setting from unloaded to loaded condition is

normally between 5-1 1 mmforthe conical mounting. Foundation

Thesupport of the individual conical mounting can be

made in one of the following three ways:
Method 2
m

Method 3
L3
Supporting
steel shim
'Min. necessary distance
"Min. thickness of steel shim 75 mm ior Steel shim
replacement of the conical mounting ChocMast

Fig 1 Resilient mounting of generating sets. LFoundation

Fig 2 Support of conicals.

----- - --
--===
---W--
PT-
= -
=

CENERATYUC SETS
 ZJMD
519.03
Edition 03H
Resilient Mounting of Generating Sets
3) Finally, the support can be made by means of
chockfast. It is necessary to use two steel
shims, the top steel shim should be loose and
have a minimum thickness of 75 mm and the
bottom steel shim should be cast in chockfast
with a thickness of at least 10 mm.
Irrespectiveofthe method of support, the 75mm steel
shim is necessary to facilitate a possible future
replacement of the conical mountings, which are
always replaced in pairs.
- B&W
Description
Page 2 (2)
Adjustment of Engine a n d Alternator o n
Base Frame
The resiliently mounted generating set is normally
delivered from the factory with engine and alternator
mounted on the common base frame. Eventhoughthe
engine and alternator have been adjusted by the
factorywith the alternator rotor placed correctly in the
statorand the crankshaft bend ofthe engine is within
the prescribed tolerances.
 : MAN '",
! B&W !

Working card
Page 1 (4) Fitting Instructions for Resilient Mounting of GenSets
519-03.00
Edition 24
1 l

Safety precautions Special tools

E Stopped englne Plate no ltem no Note

Shut-off starting air
E Shut-off cool~ngwater
E Shut-off fuel 011
H Stopped lub. oil circulation
Press button (Block~ng- Reset)

I Description
I Hand too's l
Mounting and adjustment instruction for new Ring and open-end spanner, 19 mm
GenSet and adjustment instruction for existing Ring and open-end spanner, 24 mm
plants. Ring and open-end spnner, 41 mm
Feeler gauge, 1-2 mrr:
Measurement tool
Hydraulic jack (if necessary)
Starting position

The foundation should be welded and milled off

on shim surfaces.

Related procedure

Replacement of conicals 519-03.05

Manpower Spare and wearing parts

Working hours : 2 hours Plate no ltem no
Capacity : 2 men

Data
Data for pressure and tolerance (Page 500.35)
Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

03.50 - ESl
 Z J M D ggrw
p,
519-03.00
Edition 24
1
Fitting instructions for Resilient Mounting of GenSets ,,,,
Working card
)(,

Mounting and Adjustment Instructions for 5) Position the jacking bolt with a through-going
New Generating Sets (Method 1) of minimum 75 mm.

Make Ready for Adjustment of Conical Ele- 6) Lower the generating set until it rests com-
ments pletely on the foundation.

I f the conical elements have not been mounted by 7) Check that all the jacking bolts have full con-
the factory, they must be mounted on the prepared tact with the foundation.
brackets on the base frame. In case they have been
mounted by the factory, please start with ~ t e m4. 8) Loosen the nut (7).

I)Remove nut (7) and ring (6) from the conical 9) Turn all the internal buffers by applying a
element. spanner to the hexagon (S = 13)to check that
they can move freely.
2) Fit the conical element to the bracket on the
suspended equipment by means o i fixing the
central buffer (2). the ring (6) and nu? (7). If all internal buffers Then

3) Tighten the nut (7) by hand and simultane- Can move freely Let conical elements set-
ously block the central buffer (2) by applying a I tle for 48 hours.
spanner to the hexagon (S = 19) on the top of
the central buffer (2). Cannot be moved Turn the jacking bolts
freely clockwise to release the
4) Position the four jacking bolts in the tapped internal buffer.
holes (8) in the bottom flange.

Bracket

Jacking

E1
Foundation

Section A-A 1 Base casting 5 Top casting

2 Central buffer (spindle) 6 Ring
3 Synthetic bush 7 Nut
4 Rubber element 8 Tapped hole M12

Fig 2 Conical element.

Fig 1 Conical mounting.

 Working card
Page 3 (4) 1 Fitting Instructions for Resilient Mounting of GenSets 1 519-03.00
Ediiion24
1
Adjustment of Conical Elements after 48
Hours Settling Drill the mounting holes in the steel shim according
to the conicai base casting dimensions.
After the conical elements have been deflected
understatic load for48 hours, the loaded height (HI)
see fig l , should be measured and compared to the Mounting of the Completed Steel Shim
recommended loaded height.
13) Turn the internal buffer anticlockwise until it
10) Care must be taken, during levelling of the contacts the base casting to secure the loaded
installation, to ensure that individual mount- height of each conical element.
ings are not overloaded. The variation in laden
height should not exceed 2 mm and should 14) Lift the generating set with crane or hydraulic
ideally be less. The laden height can be meas- jack.
ured between top and base casting at H, on
two sides (see fig 1). 15) Remove all the jacking bolts

H. i H. - H; ----- 16j Position eack, completed steel shim

Ex: Average = L U H,
Number of conical elements
17) Lo~verthe generating set until it rests com-
pletely in itself.
If Then
18) Number each steel shim together with each
Difference exceeds Level the conical ele- conical element.
ment
2 mm. by adjusting the jacking
bolts - c o m m e n c i n ~with
~ Adjustment of Internal Buffer
the conical element with
the largest deviaticn. 19) Turn theinternal bufferclockwise (downwards)
until it makes contact with the steel shim or
Difference does not ex- I The height of the steel foundation.
ceed 2 mm shim can be measured.
20) Turn the internal buffer anticlockwise (upwards)
until it obtains contact with the base casting.
The difference between the two sides of a conical
mounting should not b e more than 0.5 mm. This must be four full turns.

21) Turn the internal buffertwo full turns clockwise

Measuring of Steel S h i m (downwards) and check with a feeler gauge
between the base casting of the conical ele-
11) Measure the steel shim on several points to ment and the steel shim that the internal buffer
CU
7

m obtain the highest possible accuracy during (2), see fig 1, does not touch the steel shim or
9
+ preparation. foundation.
6
0'
In
22) Tighten thenut (7) with a torque of 300 Nm and
N
In

S Fabricating Steel Shim block the central buffer (2) with a spanner (S =
z
.c
0
19) at the same time.
g . 12) Make sure thatthe minimum height of the steel
shim is 75 mm to secure a future replacement
of the steel shim.

519-03.00
Edit~on24
Fitting instructions for Resilient Mounting of GenSets
Mounting of Conical Elements on the Foun-
dation
23) Drill four mounting holes in the foundation for
each conical element, either
a) Mark the positions of the mounting holes on
the foundation through the conical element.
(Re)move the set completely so that the mark-
ings can be reached b y drilling with conven-
tional tools.
Place the set on its former posiiion by aligning
it with the drilled holes.
Working card
or
b) Drill the mounting holes in the foundation by
means of the drilling pattern from the installa-
tion drawing.
The drilling has to be done on beforehand and
the set must be aligned with the foundation
holes before the work siarts to avoid further
removal of the set.
24) Fix the conical eleven: and the steel shim to
the foundation v;i:i four bolts.
Note! Aher cornpleiicn of all works the buffer clear-
ance must be checked, see points 19,20,21 and 22.
 ZJMD -
Working card 519-03.00
p,,, p, Fitting Instructions for Resilient Mounting of GenSets iditionlS

Safety precautions Special tools

E Stopped engine Plate no Item no Note

B Shut-off starting air
E Shut-off cooling water
E Shut-off fuel oil
E Stopped lub. oil circulation
E Press button (Blocking - Reset)

Description Hand tools

Mounting and adjustment instruction for new
GenSet and adjustment instruction for existing
plants.
Starting position
Ring and open-end spanner, 19 mm
Ring and open-end spanner, 24 mm
Ring and open-end spanner, 41 mm
Feeler gauge, 1-2 mm
Measurement tool
Hydraulic jack (if necessary)

The foundation should be welded and milled off

on shim surfaces.

Related procedure

Replacement of conicals 519-03.05

Manpower Spare and wearing parts

Working hours : 2 hours Plate no Item no Qtyl
Capacity : 2 men

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

03.50 - ESl 0406

 ZJMD - B&W

1 519-03'00
Edition 25 / Fitting instructions for Resilient Mounting of GenSets / Working card
~agez(4)

Mounting and Adjustment Instructions for
New Generating Sets (Method 2)
Make Ready for Adjustment of Conical Ele-
ments
If the conical elements have not been mounted by
the factory, they must be mounted on the prepared
brackets on the base frame. In case they have been
mounted by the factory, please start with item 4.
l) Remove nut (7) and ring (6)from the conical
element.
2) Fit the conical element to the bracket on the
suspended equipment by means of fixing the
central buffer (2), the ring (6)and nut (7).
A 75 mm supporting steel shim, complete with holes
for four jacking bolts and mounting holes drilled
according to conical base casting dimensions, is
required.
4) Position the supporting steel shim as per fig 1
and locate the conical element by means of
dowel pins.
5) Position thejacking bolts in the tapped holes in
the supporting steel shim as per fig 1.
6) Position the jacking bolts with a through-going
of minimum 1C mm. see fig 1.
7) Lowed generating set until it rests completely
on the foundation.

3) Tighten the nut (7) by hand and simultane- 8) Check that all jacking bolts have full contact
ously block the central buffer (2) by applying a with the foundation.
spanner to the hexagon (S = 19) on the top of
the central buffer (2). 9) Loosen the nut (7).

10) Turn all the internal buffers by applying a

spanner to the hexagon (S = 19) to check that
they can move freely.

Steel shim -

Foundation

Section A-A
1

N
1 Base casting 5 Top casting m
F
2 Central buffer (spindle) 6 Ring D
3 Synthetic bush
4 Rubber element
7 Nut
8 Tapped hole M12
z
N
0
m
0

Fig 1 Conical mounting. Fig 2 Conical element.

 ,iMAN
ZJMD - E&W i B&W:
.,

Working card
1 Fitting Instructions for Resilient Mounting of GenSets 1 519-03.00
Edition
1
If all internal buffers 'Then Measuring of Steel S h i m
l
Can move freely Let conical elements set- 12) Measure the steel shim on several points to
tle for 48 hours. obtain the highest possible accuracy during
preparation.
Cannot be moved Turn the three jacking
freely bolts in the supporting
steel shim clockwise, or Fabricating Steel S h i m
anticlockwise to release
the internal buffer. 13) Makesure that the minimum height ofthe steel
shim is 10 mm to secure the future replace-
ment of the supporting steel shim.
A d j u s t m e n t o f C o n i c a l E l e m e n t s a f t e r 48
Hours Settling Drill the mounting holes in the steel shim according
to the conical base casting dimensions.
After the conical elements have been deflected
understaticload for48 hours, the loaded height ( H I )
see fig 1, should be measured and compared to the Mounting of the Completed Steel Shim
recommended loaded height.
14) Lift the generating set l mm totally be means
11) Care must be taken, during levelling of the of the three jacking bolts.
installation, to ensure that individual mount-
ings are not overloaded. 'The variation in laden 15) Position each completed steel shim.
height should not exceed 2 mm and should
ideally be less. The laden height can be meas- 16) Re-lower :he generating set by means of the
ured between top and base casting at H, on three jacking bolts until it rests completely in
two sides (see fig 1). itself.

H, + H, + H, ---- H,
Ex' Average = Number of conical elements A d j u s t m e n t o f I n t e r n a l Buffer

17) Turn the internal buffer clockwise (downwards)

If Then until it makes contact with the steel shim or
foundation.
Difference exceeds Level the conical element
2 mm. by adjusting the jacking 18) Turn the internal buffer anticlockwise (upwards)
bolts - commencing with until it obtains contact with the base casting.
the conical element with
the largest deviation. This must be four full turns.
N
F

m
Difference does not ex- The height of the steel 19) Turn the internal buffer two full turns clockwise
9 ceed2mm shim can be measured. (downwards) and check with a feeler gauge
e
m
0 between the base casting of the conical ele-
N
m ment and the steel shim that the internal buffer
!
! zo The difference between the two sides of the conical
mounting should not be more than 0.5 mm.
(2), see fig l , does not touch the steel shim or
foundation.
i 0
m
0

20) Tighten the nut (7) with a torque of 300 Nm and

block the central buffer (2) with a spanner (S =
19) at the same time.
 MAN :.
r. E & W L ZJMD
Ed~tion25
Fitting Instructions for Resilient Mounting of G e n S e t s
Mounting of Conical Elements on the Foun-
dation
21) Remove the dowel pins.
22) Drill four mounting holes in the foundation for
each conical element, either
a) Mark the positions of the mounting holes on
the foundation through the conical elemen:.
(Rejmove the set completely so thatthe mark-
ings can be reached by drilling with conven-
tional tools.
Place the set on its former position by aligning
it with the drilled holes.
- E&W
Working card
page 4 (4) .
b) Drill the rnount~ngholes in the foundation by
means of the drilling pattern from the installa-
tion drawing.
The drilling has to be done on beforehand and
the set must be aligned with the foundation
holes before the work starts to avoid further
removal of the set.
23) Fix the conical element and the supporting
steel shimlsteel shim to the foundation with
four bolts.
24) Weld the lowest steel shim to the foundation.
Note! After completion of all works, the buffer clear-
ance must be checked, see points 17, 18. 19
and 20.
 i' MAN ',
B&W

Working card
Page I(4) I Fitting instructions for Resilient Mounting of GenSets 1 519-03.00
Edition 26
1

Safety precautions Special tools

Stopped engrne Plate no ltem no Note
B Shut-off start~ngalr
!l? Shut-off cooling water
E Shut-off fuel or1
E Stopped lub oil circulation
E Press button (Blockrng - Reset)

Description Hand tools

Mounting and adjustment instruction for new
GenSet and adjustment instruction for existing
plants.
Starting position
Ring and opep-end spanner, 19 mm
Ring and open-end spanner, 24 mm
Ring anc open-end spanner: 41 mm
Feeler gauge. 1-2 mm
Measuremant to31
Hydraulic jack (if necessary)

The foundation should be welded and milled off

on shim surfaces.

Related procedure

Replacement of conicals 519-03.05

Manpower Spare and wearing parts

Working hours : 2 hours Plate no ltem no
Capacity : 2 men

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

p-

03.50- ESO 0406

 ZJMD -
Edition 26
Fitting Instructions for Resilient Mounting of GenSets ,,,,,,,,
Working card

Mounting and Adjustment lnstructions for
New Generating Sets (Method 3)
Make Ready for Adjustment of Conical Ele-
ments
If the conical elements have not been mounted by
the factory, they must be mounted on the prepared
brackets on the base frame. In case they have been
mounted by the factory, please start with item 4.
l) Remove nut (7) and ring (6) from the conical
element.
2) Fit the conical element to the bracket on the
suspended equipment by means of fixing the
central buffer (2): the ring (6) and nut (7).
3) Tighten the nut (7) by hand and simultane-
ously block the central buffer (2) by applying a
spanner to the hexagon (S = 19) on the top of
the central buffer (2).
A75 mmsupportingsteel shim, completewith tapped
holes forthree jacking bolts, four mounting holes and
four tapped holes, drilled according to the conical
base casting dimension, is required see fig 1.
4) Position the supporting steel shim as per fig 1
and locate the conical element by means of
four hold-down bolts.
5) Position the jacking bolts in the tapped holes in
the supporting steel shim as per fig 1.
6) Position the jacking bolts with a through-going
of minimum 10 mm plus permitted thickness,
as spezi-Zed from the chockfast supplier, see
fig :.
7) Lowed the generating set until it rests com-
p l e t e ! ~on the foundation.
8) Check that all jacking bolts have full contact
with the foundation.

Foundation
G : .El 1 Base casting 5 Top casting
I Mounting boft-, Section A-A
- 1

2 Central buffer (spindle) 6 Ring

3 Synthetic bush 7 Nut
4 Rubber element 8 Tapped hole M12

Fig 2 Conical element.

Fig l Conical mounting.

 ZJMD - E&W

Working card 51 9-03.00

~age3(4) Fitting Instructions for Resilient Mounting of GenSets

M e a s u r i n g o f Steel S h i m a n d C h o c k f a s t

Can move freely Let conical elements set- 10) The steel shim should be at least l 0 mm heigh.
tle for 48 hours.
Check the minimum permitted thickness of
Cannot be moved Turn the three jacking chockfast for the load and surface of this appli-
freely bolts in the supporting cation with chockfast supplier.
steel shim clockwise, or
anticlockwise and
slacken the four hold- F a b r i c a t i n g Steel S h i m
down bolts to release the
internal buffer. Make sure that the minimum height ofthe steel shim
is 10 mm to secure a future replacement of the
sirppofiing steel shim.
A d j u s t m e n t o f C o n i c a l Element after48 H o u r s
Settling 11) Diil; the mour,tjng holes in the steel shim
accordi~gto tile mounting holes in the sup-
After the conical elements have been deflected porting steel shim.
under staticload for48 hours, the loaded height ( H I )
see fig 1, should be measured and compared to the
recommended loaded height. A d j u s t m e n t of I n t e r n a l B u f f e r

9) Care must be taken, during levelling of the 12) Turn the internal buffer clockwise (downwards)
installation, to ensure that individual mount- until it makes contact with the steel shim or
ings are not overloaded. The variation in laden foundation.
height should not exceed 2 mm and should
ideally be less. The laden height can be meas- 13) Turn the internal bufferanticlockwise(upwards)
ured between top and base casting at H, on until it obtains contact with the base casting.
two sides (see fig 1).
This must be four full turns.
H, + H, + H, H,
Ex: Average = 14) Turn the internal buffertwo full turns clockwise
Number of conical elements
(downwards) and check with a feeler gauge
between the base casting of the conical ele-
If Then ment and the steel shim that the internal buffer
l (2), see fig 1, does not touch the steel shim or
Difference exceeds Level the conical element foundation.
2 mm. by adjusting the jacking
bolts - commencing with 15) Tighten the nut (7) with a torqueof300 Nrn and
the conical element with blocking the internal buffer (2) with a spanner
.--
N

m
the largest deviation. at the same time, see fig 1.
0
i
P
In
0

-
In
N
Difference does not ex-
ceed 2 m m 1
1
The height of the steel
shim and the chockfast
can be measured.
M o u n t i n g of C o n i c a l E l e m e n t s o n t h e F o u n -
dation

16) Drill mounting holes in the foundation accord-

The difference between the two sides of the conical ing to the supporting steel shimistee1 shim and
mounting should not b e more than 0.5 mm. chockfast, either
 ZJMD - B&W

519-03u00
Edition 26
n s Resilient Mounting of GenSets
Fitting l n ~ t r ~ c t i o for ,,
Working card

a) Mark the positions of the mounting holes on

the foundation through the supporting steel
shim. b) Drill the mounting holes in the foundation b y
means of the drilling pattern.
(Re)move the set completely so that the mark-
ings can be reached by dr~llingwith conven- The drilling has to be done on beforehand and
t~onaltools. the set must be aligned with the foundation
holes before the work starts to avoid further
Place the set on its former position by aligning removal of the set.
it with the drilled holes.
Make sure that the mounting bolts are isolated from
the chockfast.

Note! After completion of all works, the buffer clear-

ance must be checked, see points 13,14,15 and 16.
 ZJMD - B&W

Working card
Page 1 (2) Replacement of Conicals 1 519-03.05(
Edition 02H

l
Safety precautions Special tools

C Stopped engine Plate no ltem no Note

Shut-off startlng arr
Shut-off coollng water
Shut-off fuel oil
Stopped lub. oil circulation
Press Block~ng- Reset

Description Hand tools

Replacement of conicals. Hydraulicjack

Starting p o s i t i o n

Safety precautions.

Related p r o c e d u r e

Fitting instructions for resilient mounting.

Spare and wearing p a r t s

Working hours : hours Plate no ltem no Qtyl

Capacity 2 men
51903 013 4/E

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declarationof weight (Page 500.45)

re== -
=----
98.41 - ESO 0406 ---
=
--
---m-
-- ---
CUUERATWC SETS
51 9-03.05 Replacement of Conicals Working card
Edition 02H Page 2 (2)

Replacement of Conicals

l) Loosen allthe holdingdown-boltsforthe conicals 3) Lift the GenSet until the steel shim can be
in one side. removed. This will give enough space for
removing damaged conical.
2) Mount a jack under the base frame, see fig I.
4) Mount the GenSet conical.

Note: Conicals sho~~idonlybe

replaced inpairs, see
fig 2 andplate 51903.

Conical mounting
Adjusting screw
Holding down bolts
Steel shim
7)
-3d,
1-I p-

i
\k.\\\,?
5)

6)
Lowerthe GenSet again.

Repeat items 1-5 for the other side.

Adjust the conicals, please see working card

Foundation !-
5 19-03.00 "Fitting lnsfrucfions for Resilient
Bracket
Mounfing of GenSef.

Deck

Jack

Fig 1 Removal of conicals

One pair Y
Fig 2 The conicals must be replaced in pairs

98.41 - ESO
 ZJMD -
Working Card
Maintenance of Conicals 519-03.10
Page 1 (2) Edition 02H

Safety precautions Special tools

Stopped englne Plate no ltem no Note

@ Shut-off starting air
Shut-off coolrng water
Shut-off fuel oil
Stopped lub. oil circul.
Press Blocking - Reset

Description Hand tools

Control and adjustment of conicals. Ring and open-end spanner

Feeler gauge, 2 mm.

Starting position

Related procedure

Manpower Replacement and wearing parts

Working time : 2 hours Plate no Item no Qtyl

Capacity 1 man

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

I 98.41 - ESO W06 --

E
-=--=--=
~~---TR~E?S
-S
519-03.1 0 Working Card
Edition 02H Maintenance of Conicals Page 2 (2)

L16124

Visual Check Result of Clearance Check

What to Check If 1 Then

everything is OK check is completed

1) Check for oil deposits on the rubber element.
everything is not OK adjust conicais which do not com-
2 ) Check for loose mounting bolts. ply with the clearance demands
acc. to item 5-10. Recheck
Check for damage in the rubber element. all conicals acc. to item 4.
3)
everything is stiii no; OK re?lace conical acc. to
Result of Visual Check
Working Card 579-03.05

If Then
everything is OK continue to next conical Adjustment of Conicals
oil deposits on rubber clean rubber element
element are observed
5) Remove protective cap by loosen the nut (l).

6) Turn internal buffer (2) clockwise until it makes

loose mounting bolts

damage to conicals
l fasten mounting bolts

replace conical according to

contact with the steel shim (4).

is observed Working Card 519-03.05 7) Turn internal buffer (2) anti-clockwise until it
makes contact with the conical base casting
(3). This must be done in four full rotations.
Clearance Check
8) Turn internal buffer (2) two full rotations
What to Check clockwise. This will ensure full vertical
movement for the buffer.
4) Check clearance on all conicals between steel
shim and internal buffer through the slot in the 9) Check all conicals again
base casting of the conical (see fig 1) with a
feeler gauge of approx. 2 mm. 10) Tighten the nut (l), seepage 500.40and atthe
same time block the internal buffer (2) with a
spanner.

1. Nut
2. lntemal buffer
3. Conical base casting
4. Steel shim

Fig I Conical

98.41 - ESOS
 Plate
Page 1 (2) Flexible External Connections 51902-04H

99.09 - ESO 0406 - ----

---
--
E
---
-- --
L &!E =S

GENERATNC SETS
-
--
 i+ MAN G

i B&W '

51902-04H Flexible External Connections Plate

Page 2 (2)

-
- -----
--
--
= F E
-
-- -
- - - m - -

G3ERArIhc SET5
-S=-=
0406 99.09 - ESO
 ZJMD - B&W

Plate
Page I (2) Conical Element 51903-02H

Note! When ordering be aware that conical ele- Bemzrk! Ved bestilling af conicals elernenter skal
ments always should be replaced in pairs. State conicals elernenter altid udskiftes parvis. Opgiv
manufacturing No of existing conical elements. fabrikationsnr. p i eksisterende conicals ekrnenter.

97.49 - ESO
 51903-02H Cor~icalElement Page
Plate
2 (2)

m
o; ' / Qty 1
l
Des~gnation Benawnelse
Item
No Qty 1 Designatton Benrevnelse

013 1/M I Con~calelement,

; complete
Kon~skunderstntntng,

025
l 4/M 1 Screw
kornplet

Skrue

1
l

I
I
l
l
I
I
l
1 , '

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs5 side 500.50
* =
.-
Only available as part of a spare parts kit. = Kun tilgaengelig som en del af et reservedelssaet.
Qty/M = QtyIConical mounting. Qty/M = Qty/Conical rnontering.

97.49 - ESO
 MAN
ZJMD --/B&W\
Tools

i ~ u n c t i o nof the hydraulic tools i520-01.05fa2H> 1!

7

l ~ ~ ~ l i c a of
t ~hydraulic
on tools :52o-Q:.06 (05H) i
!Hand lever pump 520-01.07(OlH) 1

JTOOI S for cylinder head

[TOOIS for piston, connecting rod and cy!inder liner 152005-OEZ j
. . . . ~ - ~

!Tools for carnsh~f7and c a m s h a t drive 52r~s7-022

Tools for operztlng gea: i o - ~nle:and exhaust valves 52f108-G7H
/Toois for crankshaft and maln bearings 52fsf 0 - G 5 H i
!
/TOOIS for charge a r cooler /52~~2-03~ i

/TOOIS
-
for fuel oil system and injection equipment i5201-4-062 I

j
h

r
:Tools for lubricating oil cooler i5202.5-94E
i
l i
I ~ y d r a u l i ctools ;52021-09E
- i
 Working Card 520-01.05
Page I (7) Function of the Hydraulic TOOIS Edition 02H

General

Safety precautions Special tools

Stopped engine Plate no Item no Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
U Stopped lub. oil circul.
Press Blocking - Reset

Description Hand tools

i Safety hints and function of hydraulic tools

Starting p o s i t i o n

Application of hydraulic tools 520-01.06

Related procedure

Manpower Replacement a n d wearing p a r t s

Plate no Item no Qtyl

W
0
Data for pressure and tolerance (Page 500.35)
Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

99.43- ESO -
L
===
= E- L = -
GENERPITlNG SETS
 ZJMD
520-01.05
Edition 0 2 ~ Function of the Hydraulic TOOIS
General
F u n c t i o n of the Bolt Tensioning Device
In order to achieve an optimal result with one or
several devices, some rules have to be considered.
We expressly point out that a conscientious handling
of the device as well as the accessories is of highest
importance. To ignore these rules or separate hints
meansdangerto life or danger of injuries! See Safefy
Hints.
Safety Hints
Beside regarding the general accident-prevention
rules, thesafe handling ofthe device and the hydrau-
licaccessories demand especially the consideration
of the following hints. When disregarding even single
items, you can cause danger to life andlor danger of
injuries!
l . When leakages occur during the pressuriza-
tion, bleed pressure immediately and seal the
leakage or replace defect parts.
2. In case of repair, use exclusively original spare
parts. lnexperi substitution of damaged parts
by non-original spare parts is prohibited.
3. All assembly parts are to be handled in corre-
spondence to the working cards only. Achange
in the procedure or another operation of the
device is not allowed.
4. Make sure that the components to be tensioned
do not exceed the admissible strain.
5. In orderto use the device, the thread has to be
sufficiently exceeding in orderto avoid that the
turn of a thread cracks, see item 4.
6. During the pressurization the people involved
have to remain in an appropriate distance.
Staying in direction towards the bolt axis is
forbidden.
7. Tensioning pressures or tensioning forces are
to be given or changed b y authorized person-
nel only while considering the admissible com-
ponent loads, see item 4.
F - *-=.S
=CENl3?AUC
=L=.= SETS .
0406
- S&W
Working Card
Page 2 (7)
8. The operation and handling ofthe deviceare to
be carried out by expert staff only.
9. The given max. operation pressure is not to be
exceeded in any case and is to be watched at
the manometer of the pressure generator dur-
ing the complete tensioning or loosening pro-
cedure. When having achieved the given pres-
sure, stop the pressurization immediately.
10. During the pressurization when tensioning or
loosening the bolt connection, always watch
the adrnissiblestroke ofthe device. Exceeding
this stroke is connected with insufficient gener-
ating of tensioning force because the device is
tensioned in itselve orthe hydraulic pressure is
bleeded automaticly.
11. On principle, when connecting high-pressure
hoses it has to be taken care that the connec-
tions are correct (see also separate hints).
12. The hydraulic hoses have to be installed in a
way that they are not run over by vehicles or
unnecessarily walked over by people. Never
lay hoses across sharp objects (danger of
cuts) and never bend or jam them in.
13. Never hold ortransportthe device by using the
high-pressure hoses.
14. An incorrect working manometer that doesn't
show the right pressure leads to overstressing
of the parts and to an incorrect bolt connection.
Apart from damaged parts an incorrect bolt
connection can also cause conditions that are
danger to life. Therefore take care that the
manometer shows the right value or the
tensioning force is checked inan other way (for
example by using a master manometer). 2
Tensioning forces can be checked for example 8
by measuring the linear deformation. Dam-
aged manometers have to be exchanged im-
3
mediately. I"
99.43 - ESO
 Rc"~@~--~"
1 MAN
ZJMD - BSW

Working Card 520-01.05

Page 3 (7) Function of the Hydraulic Tools Edition 0 2 ~

General

Working Hints
securing r i n g
l
In order to achieve a bolt connection of high preci-
sion, it is vital to considerthe following working hints:

- Prior to setting the device, clean all threads

and remove possible damages in order to
avoide a "freeze on".

- The base plate for the device must be plain and

free of dirt. Further check the squareness
towards the bolt axis in order to avoid that the
bolt has a bending stress during the pressuri-
zation (tensioning).

- The stroke of the device may not at any point

be exceeded.

- For transporting the device it is necessary to

uncouple all high-pressure hoses. Fig. l. Turnable connection unit.

- After each pressurization, bring the device

back to zero, see also Piston Return Stroke. Exchange o f the Seals

Should leakages show up at the connection unit, it

T u r n a b l e C o n n e c t i o n Unit might be necessary to exchange the seals.
For doing so, loosen the securing ring and take the
In order to simplify the connection of the hydraulic disc off the bolt nipple. Having removed the seals,
hose, a turnableconnection unit ismounted onsome clean the components with fluff-free cleaning mate-
devices. riai. You can also apply compressed air. Having
The turnable connection unit consists of the follow- checked the components for damages and oiled
ing components: them slightly, apply new seals by help of the entry
guide and reassemble the turnable connection unit.
- bolt nipple
- disc Hint: - For the cleaning, never use aggressive
- seal cleaning liquids.
- securing ring - For oiling the parts, use exclusively hydrau-
lic oil.
Furthermore, an entry guide is available or con- - For replacements, use. exclusively new
.-
N

W
tained in the scope of supply, see fig. 1. seals.
0

Coupling of the High-Pressure Hoses

- Only couple when the hydraulic system is in a

pressureless condition.

- To produce a high-pressure connection, put

one coupling and one nipple into each other
while the coupling socket is pulled back. When
letting the coupling socket go, there is a form
fit barring the connection.

99.43 - ESO
 520-01.05
Edition 0 2 ~
Function of the Hydraulic TOOIS
General
- By drawing the hose with a manual force of
about 100 N make sure that the connection is
correctly barred.
- For decoupling the high-pressure hose in a
pressureless condition, first pull back the cou-
pling socket and then take off the hose.
Screw connection
Fig. 2. Coupling o f the high-pressure hoses.
Hoses with fast-lock coupling sockets avoid, aiso
when uncoupled, that oil runs out. When the hoses
get heated, there can be an inside pressure in the
uncoupled condition making a coupling impossible.
By loosening one screw connection (see fig. 2) the
pressure can be bleeded
- To avoid a contamination use protecting caps
for the sockets.
Tensioning Procedure
Prior to the tensioning procedure make sure that the
components to be tensioned are correctly positioned
towards each other. Then screw the device onto the
bolt.
First put the support sleeve on the bolt and align it
centrically to the bolt axis. When screwing on the
device take care that the support sleeve at the
cylinder is correctly centered (consider centering
I
I shoulder).
Screw the device until the support sleeve or the
support cylinder fits exactly to the flange. The piston
l
of the device must b e at its zero position. Further-
more, take care that the hydraulic connector and the
window for the adjusting rod is well accessible.
Working Card
Page 4 (7)
If necessary, turn back the device, but make sure
that the max. admissible stroke of the device is not
exceeded. Beside that, it has to be ensured that the
cylinder and the support sleeve remain centrically
towards each other (consider centering shoulder).
Having made all hydraulic connections correctly,
see fig. 2, start the pressurization for the tensioning
procedure. If the necessary pressure is achieved
stop pressurization. The inducted force causes the
bolt to extend or an edging of the components to be
tensioned so that the main nut is lifted from the
flange. Screw it backto the flange, see fig. 3. Check
by help of a feeler gauge leaf whether the main nut
really fits tight to the flange. After that, bleed hydrau-
lic pressure. NOWthe connection is tensioned.
Having brought the piston to its zero position, see fig.
4, the hydraulic hoses can be decoupled. In order to
prevent impurities, it is advisable to close coupling
sockets and coupling nipples at once by protecting
caps. The device can be unscrewed from the bolt.
-+ Always consider the safety and working
hints!
L o o s e n i n g Procedure
In order to loosen an existing bolt connection, screw
the device onto the bolt. First put the support sleeve
on the bolt and align it centrically to the bolt axis.
When screwing on the device take care that the
support sleeve at the cylinder is correctly centered
(consider centering shoulder).
The piston of the device must be at its zero position.
Having screwed the device down until the support
sleeve or the support cylinder fits tight to the flange,
turn back the device by at least the value (slit 2
measure) which the bolt and the components spring
back elastically during the loosening procedure.
gm
P
S
(D
N
(D
Hint: The adjusted slit measure may never exceed
0
the admissible stroke of the device! Furthermore,
take care that the window ior the adjusting rod are
z
g
well accessible. m
0
Having made all hydraulic connections correctly,
see fig. 2, start the pressurization.
99.43 - ESO
 Working Card
Page 5 (7) Function of the Hydraulic Tools
During the pressurization, a slightturn-back momen-
tum is applied to the main nut with the adjusting rod.
At the moment, when the main nut can be loosened,
interrupt the pressurization. Should it not be possible
to loosen the main nut when achieving the original
tensioning pressure, interrupt the pressurization
immediately. Find the cause with expert staff.
Having achieved the loosening pressure, turn back
the main nut by the value that the bolt and the
components spring backduring the loosening proce-
dure. Theslit measure, however, must be lower than
the slit measure adjusted at the device before, see
also hint b.
The main nut may never be turned back until it fits to
the piston or the cylinder since then the device can
be tensioned in itself.
Having turned back the main nut, the pressure can
be bled. The bolt connection is loosened. Before
unscrewing the device, bring the piston back to its
zero position, see fig. 4. After that, the hydraulic
hoses can be decoupled. In order to prevent inpuri-
ties, it is advisable to close coupling sockets and
coupling nipples at once by protecting caps. The
device can be unscrewed from the bolt.
+ Make sure that n o operational forces (e.g.
inner pressure) affect the components to be
loosened since only part of the bolts take over
these forces and thus the bolts, which are not
yet loosened, might be overburdened.
+ The pressure when the main nut can be loos-
ened may never exceed the tensioning pres-
sure by help of which the connection was
tensioned! Should it not be possible to loosen
the main nut when reaching the original
tensioning pressure interrupt the pressuriza-
tion immediately. Find the cause with expert
staff.
-+ Always consider the safety and working hints!
-
99.43 ESO
520-01 .OS
Edition 02H
General
Hint:
a) Should it be impossible to unscrew the device
after the depressurization, it has been turned
back by a too low measure prior to the pres-
surization. Pressurize again until the original
tensioning pressure is reached, turn the main
nut and bleed the pressure again (tensioning
procedure). Now you can turn back the device
further. (Atfention: consider the admissible
stroke of the device!) Now repeat the loosen-
ing procedure explained above.
b) Should it be impossible to loosen the main nut
after the depressurization, it has been turned
back by a too low measure prior to the pres-
surizati~n.Pressurize again and turn the main
nut fu-the- back. Bleed the pressure again.
Hint: Never screw the main nut back unt~lit fits to the
piston since the device can be tensioned in
itsel'.
Adjustment a n d Turn Back of t h e Main Nut
During the pressurization of the device, the bolt is
being extended by the tensioning force and the
components are being edged. The result is that the
main nut does no longer fit to the flange.
Having achieved the necessary pressure, adjust the
main nut - when tensioning - until it fits to the flange
again before bleeding the pressure, see Tensioning
Procedure. When loosening the bolts, turn back the
main nut after the pressurization according to the
bolt and component deformations, (see Loosening
Procedure.
Hint: During the loosening procedure, never turn
back the main nut until it fits to the piston or the
cylinder since the main nut sticks after the depressu-
rization.
The main nut is equipped with several radial bores
where the adjusting rod can be put in. The main nut
is accessible through the window in the support
sleeve.
520-01.05 Working Card
Edition 02H
Function of the Hydraulic Tools Page 6 (7)

General

During the piston return stroke, considerable back-

window pressures can occur in the piston area of the device
since quite large quantities of oil have to flow back
through the small cross sections of the high-pres-
sure connections.

In order not to unnecessarily increase the force for

the piston return stroke turn the piston slowly. On
principle the piston of the device has to be pushed
back until it fits to the cylinder again.

I i
E x c h a n g e o f t h e Seals
Fig. 3Adjustment and turn back of the main nut.

Should leakages occur at the piston of the device, an

exchange of the seals might be necessary.
Piston Return Stroke
Drive out the piston by carefully beating with a
hammer while using a plastic spacer in order to
After each pressurization it must be ensured that the
protectthe device from unnecessary damages. After
piston of the device is brought back to its zero
removing the hydraulic connector, you can also
position. On principle, it has to be considered that
carefully lead compressed air into the piston area.
hydraulic oil is being displaced from the piston area.
In order to enable the oil to flow back to the tan^ of
Attention: Sudden input of compressed air can lead
the pressure generator, the corresponding hydraulic
to the piston's uncontrolled outlet.
connections must be done.
After removal of the piston, the seals and the backup
rirlgs can be removed from the piston and the cylin-
The piston retum stroke is done by a screw-down at
der.
the bolt itself before the device is taken off.
Carefully clean the components with fluff-free mate-
Hint: When using fast lock coupling elements, the
rial and check them for damages. If necessary, use
oil's running out and thus a piston return stroke in an
compressed air for the cleaning, but never aggres-
uncoupled condition is impossible!
sive cleaning liquids. After that, slightly oil these
components with hydraulic oil and assemble new
backup rings as well as new seals to the piston and
the cylinder according to the drawing.

I I

Fig. 4. Piston return stroke.

Fig. 5. Exchange of the seals.

99.43 - ESO
 ZJMD - B&W
-
Working Card 520-01.05
Page 7 (7) Function of the Hydraulic TOOIS Edition 0 2 ~

General

As shown in the picture, first assemble the backup

ring, then put the seal onto the backup ring. Piston
and cylinder can now be assembled again by putting
the components together. By slightly hammering on
the piston (with plastic spacer), it can be driven in
until it fits tightly to the cylinder (piston in its zero
position). It is essential that the piston does not tilt
during being driven in since this might damage the
seals as well as the components. When assembling
the piston it has to be taken care that the air can
come out of the piston area.

Maintenance and Storage

Regular maintenance of the device is not necessary,

but you should consider the following points:

a) Storage

After each operation, repair possible damages and

clean the device in order for it to be ready for the next
operation immediately. In order to avoid a corrosion
it is advisable to oil the device and especially its
thread. All coupling nipples, coupling sockets and
also loosened screw connections are to be closed by
protecting caps.

In addition, check the components of the device and

its accessories for completion.
Keep the device in the tool box also offering protec-
tion from mechanical damages.
The temperature must be between -20 C and +70 C
in order to exclude a damage of the seals.

b) Start-up o f the device

Prior to the device's operation, repair possible dam-

ages and clean the device.
2
* Check the components o f the device and its acces-
9
* sories for completion.
0
m
m
N
The operating manual has to be read by all users.
0
0

99.43 - ESO
 ZJMD - E&W

Working Card 520-01.06

Page 1 (4) Application of Hydraulic Tools Edition 06H

1 Safety precautions Special tools

l
H Stopped engine Plate no Item no Note
Shut-off starting air
Shut-off cooling water See page 2-4
E Shut-off fuel oil
E Stopped lub. 011c~rcul.
E Press Blocking - Reset

Description Hand tools

Application of hydraulic tools.

Starting p o s i t i o n

Function of hydraulic tools 520-01.05

Related p r o c e d u r e

Manpower Replacement and w e a r i n g p a r t s

Working time : hours Plate no Item no Qty!

Capacity men

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

01.35 - ESO
 520-01.06 Application of Hydraulic TOOIS
Working Card
Page 2 (4)
Edition 06H

This working card gives the information for application

of hydraulic tools, to be used in connection with
working card 520-01.05.

52021-072 /
Pressure p a r t y
)

Hose with union

52021-202

Fig I Spur gear.

Pressure part
52021-096

Hydraulic tightening

Hose with union

52021-202

Hose with union

52021-011 52021-202

Fig 2 Cross bolt and tierod.

--
r _I=
=-RATING
=
-S
=
==--
C5
-
-r
-
PETS
a406
01.35 - ESO
 Working Card
Page 3 (4) Application of Hydraulic Tools
l 520-01.06 1
Edition 06H

Pressure part, 52021-059

Hydraulic tightening, 52021 -287
Ass. tension screw, 52021-1 18
Hydraul~ctightening, 52021-275

Hose with union

Hose with union

52021-180 Pump
52021-011

Fig 3 Connection of hydraulic tools.

. Pressure part
52021-072
.Hydraulic tightening
52021 -287

h
h
\ Hose with union
52021-202
Pump
52021-01 1

Fig 5 Afler main bearing.

Hose with union

52021 -1 80
\ DistribuSon piece
52021-143
Hose wih union
PU~D 52021-202

Fig 4 Main bearing

 520-01.06 Working Card
Edition O ~ H Application of Hydraulic TOOIS Page 4 (4)

H o s e with unlon

Distribution plece
52021-1 67
Pump
52021-01 1

Fig 6 Counter weight and connection rod.

-- ---
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= *==
- - m

~-TKc?E?s
FE-=-
0406 01.35 - ESO
 ZJMD - B&W
MAN

Working Card 520-01.07

Page 1 (4) Hand Lever Pump Edition 01 H

General

I Safety precautions Special tools

El Stopped engine Plate no ltem no Note

Shut-off starting air
Shut-off coo!ing water 52021 011
Shut-off fuel oil
B Stopped lub. oil circul.
Press Blocking - Reset

Description Hand tools

Application of hydraulic tools.

Starting position

Related procedure

Manpower Replacement and wearing parts

Working time : hours Plate no Item no Qtyl

Capacity men

Data

Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

~-
- ~

99.43 - ESO --
- -- -
-v---
ys===
C E W T Y U C SETS
 520-01.07
Edition 01 H
Hand Lever Pump
General
Warning: The hand lever pump is not equipped with
a pressure relief valve.
Never use the pump without a mounted manometer.
Always pay attention to the given pressure of the
connected pressure consumers. Do never exceed
this pressure or the max. pressure of the hand lever
Pump.
Important: Except for hydraulicoil, never use different
liquids such as petrol, water, diesel oil, alcohol or
brake liquid, since these can lead to damages or
even to destruction of the pump andlor the parts
connected with it. Choose a place of assembling and
operation where the pump can always stand safe
and firm on a horizontal plain. There should always
be sufficient space for operating the pump. i
Never handle the pump lever with oiled hands and
never use hand lever exensions. Never expose the
pump to great heat, fire or extrerne coldness, since
this leads to damages or even destruction. Protect
the pump from falling objects and avoid hard blows
or pushes.
Attention - Danger t o life
Check the manometer of the pump for the needed
hydraulic pressure, given by an authorized person,
notto be exceeded. Make sure thatthe pressure you
want to generate is also admissible forall connection
parts.
All pressure connections and connecting elements
have to be clean and undamaged. High-pressure
connections from the pump to the tools have to be
established correctly prior to any pressurization.
Disregard leads to dangerto life. Please see working
card 520-0 I.06.
-
Attention Danger on injuries
Loads being liffed by the pump may neverbe held by
the pump valves alone. Use additional non-return
valves or safetyrelief valves and secure the load by
sufficient support against falling.
%
-=---
=--
= F
GENERA-
* -SETS
0406
Working Card
Page 2 (4)
Initial S t a r t - u p a n d V e n t i n g
In general and venting
Pleasemakesure that all partsofthe pump, especially
the manometer and the pressure port, are in a
perfect condition. Defect parts are to be exchanged
against new ones immediately.
Turn the carrying handle with counter-clockwise
rotation out of his fixing. Then turn it into the hand
lever of the pump against the stopping face.
Attention: lfthe carrying handle is notsrewed-in into
the hand lever, it can cause injuries while using the
pump.
Open the oil filler cap and check the oil level. If
neccessary. fill up thetankwith hydraulicoil according
to IS0 VG 32. Never overfill the tank. Close the oil
filler cap.
Open the tank breather with the square wrench
(included in the scope of supply) by about one turn.
Now loosen the breather screw at the pump (see
drawing) with an allen key SW 2,5 by about one turn.
Close the depressurization valve tightly. Now pump
at the hand lever until oil flows out of the breather
screw bladder-free. Only then are you allowed to
close the breather screw. The pump is now vented
and ready for operation.
After each operation and for the transport, close the
tank breather in order to avoid the hydraulic oil's
running out.
Pressurization
- Open the tank breatherwith the square wrench
approx. one turn.
N
?
m
0
Remark: The pump isonly to be operated with open
tank breather.
- Close the depressurization valve at the pump
when turning clockwise by handoperation.
Remark: The depressurization valve is designed for
manual operation. 'The use of any tools at the
depressurization valve could cause damages of the
valve or the valve seat.
99.43 - ESO
 Working Card 520-01.07
Page 3 (4) Hand Lever Pump Edition 01 H

General

- Pump at the hand lever until the wanted pres-
sure is achieved. Check the pressurization at
the manometer and take care of possible
leakages.
Remark: The pump is w ~ t htwo stages. The change
from the first stage to the second stage happens
autornatical at a system pressure of about 30 bar.
Attention: The pump is not equipped with an internal
pressure relief valve. The use of a manometer and
the control of the system pressure during
pressurization is indispensable.
Attention: Do not stand directly overthe moving line
of the pump lever. Under arising circumstances the
lever can "hit back". To avoid accidents stand
sideways the pump.
Attention: Inside of the adjusting screw is another
grub screw with inner hexagon (wrench size 4 mm)
to limit the stroke of the change-over piston inside of
the pump block. It is absolutely necessary, to screw
out the grub screw approx. 2 times before turning the
adjusting screw!
The regulation ofthe adjustingscrewfollowsgradually
in approx. 10" - steps. After everv adjusting step the
grub screw is to screw in unt~lit fits closely and
approx. a 114 turn to loosen.
Check by caref~llypumping ifthe change-over pres-
sure wanted has been reached. If necessary, repeat
the procedure as described above.

Attention - High-pressure hydraulic

On principle, tihen leakages occur during the
pressurization, immediately release the hydraulic
pressure and seal the leakage orrenew defect parts.

Depressurization
- Open the depressurization valve slowly by a
turn to the left.

- Make sure that the hydraulic pressure at the

manometer has been completely released.
Considerthereturning timeofthe hydraulicoil.

Adjustment of change-over pressure from

stage 1 to stage 2

In exeptional case, it can be useful to adjust the

N
?
change-over pressure from stage 1tostage 2 (factory
cd
9
d
adjusted at approx. 30 bar).
S
XIn Below of the pressure relief valve is an adjusting
I, screw with inner hexagon (wrench size 10 mm).
n
Turning out counter-clockwisely the adjusting screw
2
N minimizes the change-over pressure, turning in
a
m
a clockwise maximizes the change-over pressure.

99.43- ESO
 ZJMD - B&W

520-01.07 Hand Lever Pump

Working Card
Edition 01 H Page 4 (4)

General

A n a l y s i s a n d C o r r e c t i o n of M a l f u n c t i o n Pressure P o r t

Correction o f malfunctions The pressure port ofthe pump is produced according

to our customers' wishes. In addition, there is a
In case of malfunctions at the pump, the following variety of possibilities to connect the pump with one
points are to help you with the analysis of the or more pressure consumers. A selection of pres-
problem and correcting it yourself. sure ports please find in the annex.
Forthis, uncouple or unscrew all consumerand high-
pressure hoses from the pump. Attention - Danger to life
Prior to the pump' S start-up please make sure that,
no matter which pressure port you chose, all
' Malfuncbon Correction
connection elements are in a perfect condition.
Convince yourself ofthe fact that these are correctly
No pressur~zat~or 1 Checrt the 011l e e a i d I' connected and suitable for the necessary pressure.
necessa y 611 I! up as
described Ir chapte-
Attention - High-pressure hydraulic
I maintenance and storage
12 Close depressunzatlon valve On principle, when leakages occur during the

/ 3 Visual rnspectlon whether

there are leakages If so.
seal them
4 Vent the pump as descr~bed
in chapter ~nltialstart-up and
venting
Insufficient pressurization 1. Check the oil level and, if
necessary, fill it up, as
m described in chapter
(prior to any corrections, i
mainteance and storage.
open de-pressurization 12. Close depressurization valve
valve and release hydraulic 3. Visual inspection whether ther
pressure completely) are leakages. If so, seal them.
; d . Vent the pump as describes
in chapter initial start-up and
/ venting.
Pressure drop 1. Visual inspection whether
there are leakages. If so,
(prior to any corrections, seal them.
open de-pressurization 2. Close depressurization valve.
valve and release hydraulic
pressure completely).
If the problem cannot besolved, please contact MAN
B&W Diesel Holeby.
pressurization, immediately release the hydraulic
pressure and seal the leakane or renew defect parts.
Maintenance and S t o r a g e
The pump should be lubricated frequently at the
movable parts. Protect it from contamination because
dirt in the oil or in the pressure port can lead to the
pump' S failure. A dry storage avoids the steel parts'
getting rusty.
The storage and transport ofthe pump should always
be done in a horizontal position. Thus, you avoid a
possibly necessary venting of the pump during its
start-up.
For checking the oil level, please open the
depressurization valve and let the oil completely flow
back into the tank. Open the oil filler cap and fill up
hydraulic oil according to IS0 VG 32, if neccessary.
Do not overcharge the tank. Close the oil filler
=P.

The use of the pump in a dirty area requires a regular

oil change. Fill the pump with clean hydraulic oil and
lubricate all moving parts (hinges) regulary.

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! CENER4TWC SETS
 ZJMD - E&W

Plate
Page 1 (4) Tools for Cylinder Head 52005-06H

S = Standard E = Extra

02.22 - ESO - -----

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- - --
=E=-=

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52005-06H Tools for Cylinder Head Page 2 (4)

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Page 3 (4)
Tools for Cylinder Head 52005-06H

Dirnenslons y Item
Illustration of Tools Designation
P-
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A B C * N o

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II II
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Turning table for cylhnder unit E 107
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1 1

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Extraction tool for valve

seat nng E 181

I
Gr~nd~ng rnachlne for valve
seat ring incl. wooden box,
complete E 119

Grindlng stone E 183

Guide E 195

S = Standard E = Extra

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52005-06H Tools for Cylinder Head Page 4 (4)

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02.22 - ESO
 MAN '

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Plate
Page I(4) Tools for Piston, Connecting Rod and Cylinder Liner 52006082

D~menslons
lllustratlon of Tools Des~gnztion g Item
A B C ("No

Removrng deuce for S 021

flame ring

Guide bus9 fa7 p i s i o ~ S 045

p!?lg 281

Fit and removal dev~cefor S 069

connecting rod bearlng
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261
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52006-082 Tools for Piston, Connecting Rod and Cylinder Liner Page 2 ( 4 )

Dimensions g Item
lllustratlon of Tools Designation
A B C m N o

L~ftrngdevice for S 082

cylrnde; liner

Lrft~ngdevlce for prston S 104

and connecting rod

162

Test~ngmandrel for S 153

p~stonring grooves

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 ZJMD- E&W

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Page 3 (4) Tools for Piston, Connecting Rod and Cylinder Liner 5200608Z

D~menslons
Illustratron o;Tosls Desrgnat~on y Item
A B C ("No

Pl~erfor prston p n o:k rlng S IT7

C ~ ~ 2 3r "12 3 x - S i S 190

Supyrhng devl;e for S 212

connectng rod a i o p~s:onIn
the cyl~nderlrner (2 pcs)

S = Standard E =Extra

02.22 - ESO
 Plate
52006-082 Tools for Piston, Connecting Rod and Cylinder Liner Page 4 (4)

Dimenstons qItem
lllustratlon of Tools Desrgnatlon
A B C mNo

Hon~ngbrush,
~nclwooden box E 224

Wooden box
LxBxH=215~215~380rnm

M ~crorneterscrew for
connectrng rad E 236

idlca-ete- ssrev-hr
cy ncie- l re. E 248
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Page I(1) Tools for Camshaft and Camshaft Drive 52007-02H

S = Standard E = Extra

02.22 - ESO 0406

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Page I(1)
I TOOISfor Operating Gear for Inlet and Exhaust Valves 1 52008-07H 1
D~rnenslons
lllustrat~onof Tools Desrgnatron g Item
A B C m N o

Feeler gauge 0 4-0 5 m m S 010

(exhaust valve)

Feeler gauge 0 5-0 6 mm S 034

(rnlet valve)

S = Standard E = Extra

02.22 - ESO
 ZJMD - B&W

Plate
Page I (1) Tools for Crankshaft and Main Bearings 52010-05H

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Page I(1) Tools for Charge Air Cooler 5201 2-03H

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Fressure testing tool,

ldieasuring pin E 121

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Tools for Fuel oil and injection equipment

Measuring sleeve

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Page 1 (1) Tools for Lubricating Oil Cooler 5201 5-04H

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02.22 - ESO 0406 - ------- --

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Page I(4) Hydraulic TOOIS 52021-09H

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 ZJMD - E&W

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52021-09H Hydraulic Tools Page 2 (4)

Illustration of Tools Designation

I

D~stributlngplece for cyl~nder

head, complete S

I
110 mm

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I

179 +
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Distributing plece for n a i r I

bearing, complete. 1 1
Gasket

Quick coupling

Hydrauiic ~ O O ! Sfor connectins

rod, complete

Piston fo; hydraulic jack*

Set of 0-rings wi!h back-up ring

Cylinder for hydraulic jack*

Spacer piece

Angle piece complete

Hydraulicjack as item nos. 704,

716, 741

Spare parts for hydraulic tools

for connecting rod

I 'not available as a single part

S = Standard E = Extra

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Page 3 (4)
Hydraulic Tools 52021-09H

Drrnensrons g Item
Illustration of Tools Des~gnat~on
P

A I B C a N o

-
1 p->,- / 358 Hydra~lictools 'or cyl~nder l
-
I /

- - S 275
I
-+.\, head complete
-
1 ,,,, .
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z,/, ' ;J ,l / 1 P~s:orfor hydraulrc jack*
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430 429
Set oiO-rings wrth back-up rrng 430

Cyl~nderfor hydraulic jack* 442

442 059
Spacer piece, long
429
Hydraulicjackas Item Nos 429
430,442 454

Angle plece, complete 358

059 pacer plece, short 072

I
l
l
1
Tens13n screw I 118

118 I
Spare parts for hydraulrc tools
for cylinder head E 226
I 1
Spare parts kit for angle
piece E 322

p/ L L ? <
2Oi
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1
Spanner S 310

S 334
I'iommy bar
*Q e
hl
'not available as a slngle part

S = Standard E = Extra

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 52021-09H Hydraulic TOOIS Plate
Page 4 (4)

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